Systems, methods and apparatus for guided tools

ABSTRACT

The present disclosure is directed to calibrating position detection for a tool. The tool can use a sensor to detect a first value of a parameter. The tool can use a motor to extend the working member of the tool towards a working surface. The tool can include a base. The tool can detect, with the working member in contact with the working service, a second value of the parameter. The tool can determine a z-axis position of the working member relative to the working surface.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/573,465, filed on Nov. 11, 2017 and issued as U.S. Pat. No.10,456,883 on Oct. 29, 2019, which is a national stage entry ofInternational PCT Application No. PCT/US2016/032224, filed May 12, 2016,which claims the benefit of priority to U.S. Provisional PatentApplication No. 62/161,179, filed May 13, 2015, each of which are herebyincorporated by reference herein in their entirety.

BACKGROUND

Visual guides that are drawn on material may be difficult for a user tofollow manually. Further, it may be difficult to determine a position ofa tool on the material.

SUMMARY

Apparatuses, systems and methods of the present disclosure facilitateguiding a tool. In some embodiments, the system includes a rig or framewith a stage that may be positioned on the surface of a piece ofmaterial such as wood. The tool can be electrically or mechanicallycoupled to the frame, and the frame together with the tool can be passedover the material. The system can include sensors, cameras orpositioning logic to determine the tool's position on the material andaccurately move (or provide instructions for a user to move) the frame,stage, or tool to a desired coordinate on the material.

In some embodiments, the surface of the material can be marked withlocation markers that facilitate detecting a location of the toolrelative to the surface of the material. The marker can be designed orconfigured to facilitate easy, fast, and reliable detection by a sensorof the tool. In some embodiments, the marker may include a binary imageor be constructed in a manner that can be easily converted to a binaryimage. For example, the marker may include a fiducial marker that can bedetected with minimal computation power, such as a black-and-white imagethat may represent dominoes.

In some embodiments, the present disclosure is directed to a system,method or apparatus of directing or extracting dust that may begenerated while performing a task on a surface of a material. Forexample, while a cutting tool is cutting a material such as wood, sawdust may be produced which may make it difficult for the tool to detectmarkers that may be placed on the surface of the material. The tool ofthe present disclosure includes a cavity in which the dust generated bycutting the material can be directed. For example, the cavity mayinclude a void in tool frame, and a fan of the tool may direct the dusttowards the cavity. Further, a vacuum may be coupled to the tool suchthat the dust can be extracted via the channel.

In some embodiments, the present disclosure is directed to a system,method or apparatus for determining the position of a tool relative to awork surface. The system, method or apparatus can determine changes inthe force exerted by the tip of the tool (e.g., a cutting bit) in orderto determine when the tip of the cutting tool is touching or pressingagainst the surface of the material. For example, the tip of the toolmay be in a first position that is not touching the work surface. Thetip may gradually move to a second position that touches the surface ofthe material. When the tip of the tool moves to the second position, thesystem, method or apparatus can determine a change in the force, whichmay indicate that the tool tip is touching the surface of the material.For example, the force exerted on a base of the tool may be less becausethe tip of the tool is offloading some of the force from the base.

At least one aspect of the present disclosure is directed to a system tocalibrate position detection for a tool. The system can include basecoupled to the tool. The base can be in contact with a working surface.The system can include a computing device having one or more processors.The system can include a sensor communicatively coupled to the computingdevice. The system can include a motor controlled by the computingdevice. The computing device can identify, via the sensor, a first valueof a parameter indicative of an amount of force exerted by a portion ofthe base on the working surface. The computing device can instruct themotor to extend the working member towards a working surface. Thecomputing device can identify, via the sensor upon the working membercontacting the working surface, a second value of the parameter. Thecomputing device can compare the first value of the parameter with thesecond value of the parameter to generate a difference between the firstvalue and the second value. The computing device can determine a z-axisposition of the working member relative to the working surfaceresponsive to the difference between the first value and the secondvalue greater than a threshold.

At least one aspect of the present disclosure is directed to a method ofevaluating a position of a working member of a tool. The method caninclude a sensor communicatively coupled to a computing devicecomprising one or more processors detecting a first value of a parameterindicative of an amount of force exerted by a portion of a base of thetool on the working surface. The method can include a motor controlledby the one or more processors of the tool extending the working membertowards the working surface. The base can be at least partially incontact with the working surface. The method can include the sensordetecting a second value of the parameter when the working membercontacts the working surface. The second value of the parameter can beless than the first value of the parameter. The method can include thecomputing device determining a z-axis position of the working memberrelative to the working surface responsive to a difference between thefirst value and the second value greater than a threshold.

At least one aspect is directed to a system to position a working memberof a tool. The system can include a base coupled to the tool. The systemcan include a computing device comprising one or more processors. Thesystem can include a sensor communicatively coupled to the computingdevice. The system can include a motor controlled by the computingdevice. The system can include the computing device configured toidentify, via the sensor, a first value of a parameter indicative of anamount of force exerted by a portion of the base towards a workingsurface. The computing device can instruct the motor to extend theworking member towards the working surface. The computing device canidentify, via the sensor with the working member in contact with theworking surface, a second value of the parameter. The computing devicecan compare the first value of the parameter with the second value ofthe parameter to identify a difference between the first value and thesecond value. The computing device can determine a z-axis position ofthe working member relative to the working surface based on thedifference between the first value and the second value greater than athreshold.

At least one aspect is directed to a method of positioning of a workingmember of a tool. The method can include detecting, by a sensorcommunicatively coupled to a computing device comprising one or moreprocessors, a first value of a parameter for a first vertical positionof a base of the tool. The method can include extending, by a motorcontrolled by the computing device, the working member towards theworking surface. The method can include detecting, by the sensor withthe working member in contact with the working surface, a second valueof the parameter indicating a second vertical position of the base ofthe tool. The method can include comparing, by the computing device, thefirst value of the parameter with the second value of the parameter todetermine a change in vertical position of the base of the tool. Themethod can include determining, by the computing device, a z-axisposition of the working member relative to the working surface based onthe change in the vertical position of the base of the tool.

At least one aspect is directed to a system to position a working memberof a tool. The system can include a base coupled to the tool. The systemcan include a computing device comprising one or more processors. Thesystem can include one or more sensors communicatively coupled to thecomputing device. The system can include one or more motors controlledby the computing device. The computing device can determine, via the oneor more sensors, a z-axis position of the working member. The computingdevice can provide, based at least in part on the z-axis position of theworking member, motor control information to control the one or moremotors to move the working member from a first location to a secondlocation, the tool advanced in a direction that is within a rangeadjacent to a predetermined path for the working member of the tool.

At least one aspect is directed to a system to position a working memberof a tool. The system can include a base coupled to the tool. The systemcan include a computing device comprising one or more processors. Thesystem can include one or more sensors communicatively coupled to thecomputing device. The system can include one or more motors controlledby the computing device. The system can include a cavity of the tool tomove particles of material removed from the working surface by theworking member. The computing device can determine, based on firstinformation received via the one or more sensors, a first location ofthe working member. The computing device can compare the first locationof the working member with a predetermined path to determine a secondlocation for the working member of the tool corresponding to the path.The computing device can provide, based on the second location, motorcontrol information to control the one or more motors to move theworking member from the first location to the second location, the tooladvanced in a direction that is within a range adjacent to apredetermined path for the working member of the tool, the cavityconfigured to move the particles of the material in a direction oppositeto the direction in which the tool advances.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an illustrative example of an embodiment of an apparatus forautomatically guiding tools.

FIG. 2 is an illustrative example of an embodiment of an apparatus forautomatically guiding tools following a target path area and performinga task according to a planned design.

FIG. 3 is an illustrative block diagram of an embodiment of a system forautomatically guiding tools.

FIG. 4 is an illustrative flow chart of an embodiment of a method forautomatically guiding tools.

FIG. 5 is an illustrative flow chart of an embodiment of a method forautomatically guiding tools.

FIG. 6 is a block diagram illustrating a general architecture for acomputer system that may be employed to implement various elements ofthe systems, apparatus and the methods disclosed herein, in accordancewith an embodiment.

FIGS. 7A-7B are illustrative diagrams of locating markers that may beemployed to implement various elements of the systems, apparatus, andthe methods disclosed herein, in accordance with an embodiment.

FIGS. 8A-8B are an illustrative example of an embodiment of an apparatusfor directing or extracting dust particles that may be employed toimplement various elements of the systems, apparatus, and the methodsdisclosed herein, in accordance with an embodiment.

FIGS. 9A-9B are an illustrative example of a top perspective view of anembodiment of a base plate for directing or extracting dust particlesthat may be employed to implement various elements of the systems,apparatus, and the methods disclosed herein, in accordance with anembodiment.

FIG. 9C is an illustrative example of a bottom perspective view of anembodiment of a base plate for directing or extracting dust particlesthat may be employed to implement various elements of the systems,apparatus, and the methods disclosed herein, in accordance with anembodiment.

FIG. 9D is an illustrative example of a top perspective view of anembodiment of a base plate for directing or extracting dust particlesthat may be employed to implement various elements of the systems,apparatus, and the methods disclosed herein, in accordance with anembodiment.

FIGS. 10A-10B are an illustrative example of an embodiment of a systemfor determining a location of a tool tip that may be employed toimplement various elements of the systems, apparatus, and the methodsdisclosed herein, in accordance with an embodiment.

FIGS. 10C-10D are an illustrative example of an embodiment of a forcesensor positioned on an apparatus for determining a location of a tooltip that may be employed to implement various elements of the systems,apparatus, and the methods disclosed herein, in accordance with anembodiment.

FIGS. 11A-11B are an illustrative example of directing or extractingdust particles using various elements of the systems, apparatus, and themethods disclosed herein, in accordance with an embodiment.

FIG. 12 is an illustrative example of a block diagram depicting a methodof positioning a working member of a tool, in accordance with anembodiment.

FIG. 13 depicts a front view of a tool in accordance with an embodiment.

FIG. 14 depicts a front view of a tool without a working member attachedin accordance with an embodiment.

FIG. 15 provides a side view of a tool with a working member attached inaccordance with an embodiment.

FIG. 16 provides a side view of a tool without a working member attachedin accordance with an embodiment.

FIG. 17 provides a rear view of a tool with a working member attached inaccordance with an embodiment.

FIG. 18 provides a rear view of a tool without a working member attachedin accordance with an embodiment.

FIG. 19 provides a top view of a tool with a working member attached inaccordance with an embodiment.

FIG. 20 provides a top view of a tool without a working member attachedin accordance with an embodiment.

FIG. 21 provides a bottom view of the internal stage and pivotcomponents of a tool in accordance with an embodiment.

DETAILED DESCRIPTION

The present disclosure relates generally to systems and methods forworking on a surface such as woodworking or printing. In someembodiments, the present disclosure relates to determining the locationof a tool in reference to the surface of a material and using thelocation to guide, adjust or auto-correct the tool along a predeterminedpath or design plan such as, e.g., a cutting or drawing path. In someembodiments, the reference location may correspond to a design or planobtained via an online design store.

In some cases, the present disclosure can facilitate evaluating aposition of a working member of a tool. Evaluating the position of theworking member can include, for example, determining the geometry of thecutting tool or determining the geometry of a work piece (e.g., workingsurface).

Determining the geometry of the tool can include or refer to determiningthe position of the tool tip (e.g., working member) relative to areference frame of the tool. Determining the geometry of the tool caninclude or refer to determining the diameter of the cutting tool. Thetool geometry information can be used to automatically determine alength of a cutting flute of the working member and an angle of thecutter (e.g. a V carving bit or helix angle).

Determining the geometry of a work piece can include or refer todetermining or measuring the thickness of the material to be cut, orcreating a topological map of a surface by repeatedly probing it with atool tip. The tool can determine the location of features of interestsuch as holes on a work piece.

The present disclosure can use one or more techniques to determine theposition of the working member or tool tip relative to the referenceframe of the tool (e.g., tool height). For example, the tool can includea tool tip or working member and a base. The base of the tool can reston and be in contact with a working surface. A technique to determinethe position of the tool tip can include extending or dropping the tooltip onto the work surface (or a convenient flat surface such as a table)while measuring the weight on the base of the tool. When the tool tipmakes contact with the work surface, weight can be transferred onto thetool tip and off of the base of the device as additional downward motionof the cutting tool occurs. The tool can detect this reduction in weighton the base by weight sensors in the base. This technique can provideimproved accuracy in determining the position of the tool tip becausethe tool tip position can be determined within a fraction of the tooltravel necessary to lift the base of the device off of the work surface.In some cases, where the tool tip can be quite sharp, the tool tip cansink or enter into the work surface (e.g., wood) a distance beforegenerating sufficient force to cause the device to lift. However, sincethe weight sensors can be configured to detect even a small forcereduction (e.g., 1%, 2%, 3%, 5%, 0.5%, 0.1%, or 10% of the force exertedby the tool or base on the material prior to the tool tip contacting theworking surface), the tool can detect the change in force as the tooltip contacts the working surface even if the tool tip is to at leastpartially enter the working surface.

Furthermore, the tool can determine the position of the tool tip withthis technique without performing an absolute calibration of the weightsensors because the tool can determine the position based on detecting achange in the force. Therefore, it can be possible to determine theposition of the tool tip using inexpensive and uncalibrated forcesensors. Examples of force sensors can include force-sensitiveresistors, capacitive force sensors, high-pass sensors orpiezo-resistive sensors.

The tool can detect when the tool tip or working member contacts orcomes into contact with the work surface by detecting, noticing,determining, or otherwise identifying a lift of the base. The lift ofthe base may be a relatively small lift (e.g., a reduction in force onthe force sensor of 0.1%, 0.5%, 1%, 2%, 5%, 10%, 15%, 20% or some otherpercentage based on the resolution or granularity of the force sensor).In some cases, the tool can detect the lift based on a tilt of the base(e.g., 1 degree angle, 2 degree, 5 degrees, 10 degrees, 15 degrees, 25degrees or some other tilt that is detectable). The tool can detect thetilt using a camera, visual information, gyroscope, or 3-axisaccelerometer. For example, the camera can determine shift in thecaptured image corresponding to a tilt resulting from the base lifting.The camera can take a first picture or image before the tool brings thetool tip into contact with the working surface, and then take a secondimage when the tool tip contacts the working surface. The camera cancompare the first image with the second image to identify a tilt orvariation between the two images. The accelerometer can indicate thetilt responsive to a motion or sudden motion caused by the base lifting.In some embodiments, the tool can include a force sensor in the toolmount to directly measure the force on the cutting tool tip.

The tool can determine or detect additional information about the toolincluding tip or working member position, diameter, or tool geometry.For example, the tool can include a break-beam sensor (e.g. laser breakbeam sensor, infrared break beam sensor, photoelectric sensor, oroptical sensor). The working member can be dropped into the line ofaction of the sensor and the tool can detect the position of the workingmember when the working member breaks the beam. In some cases, the axisof the beam can be pre-calibrated relative to the coordinate frame ofthe tool. However, it may be challenging to accurately detect the tipposition with this technique based on the tip geometry (e.g., if the tipshape is not flat across).

The tool can determine the proximity of the tool tip to the workingsurface using a capacitive sensor or an electromagnetic sensor. Forexample, the electromagnetic sensor can sense or detect a change ininductance of a sensing coil in the proximity to the tool tip or workingmember that includes metal by sensing eddy currents induced in themetal.

Another approach is to use a vision camera aimed at the tool todetermine the position of the working member or tool tip. The visioncamera can be pre-calibrated to the tool coordinate frame to detect thetool tip. In some cases, the vision camera can include a linear chargecoupled device (CCD) sensor or other image sensor. A linear CCD sensormay use less processing than a vision camera to detect the tool tip.

The tool can measure the tool diameter using one or of these techniques.The tool can shift the tool tip around while measuring or determiningthe position of the tool tip. By shifting the tool tip, the tool can usea single break-beam sensor to detect tool diameter by passing the toolleft-to-right through the sensor. The lateral motion of the tool cancause a first break and then unobstruct the beam to provide a measure ofthe tool diameter. Since router bits can have helical flutes, the toolcan perform multiple measurements along the length of the tool todetermine the diameter. The tool can determine the diameter using eddycurrents or capacitive sensing with a one-dimensional sensor to gathermulti-dimensional information about the tool geometry by correlating thesensor data to the tool position. The tool can determine additionalinformation about the tool tip such as tip angle in the case of av-cutting bit. Furthermore, the tool can include a vision camera todetect geometric properties of the tool.

The tool can measure the geometry of the work surface by correlating thetool tip position with device position on the plane of the work surface.To do so, the tool (e.g., a cylindrical tool with a conical or sphericaltip) can first be related to the reference frame of the tool bydetecting the position of the tool tip. Once the position of the tooltip is known relative to the tool's reference frame, the tool can bepositioned laterally over a surface of interest (e.g., working surface)to determine the vertical position of the working surface. The verticalposition of the working surface can refer to a recess, cavity, indent,or concave portion in a piece of wood whose depth is of interest. Thetool tip can then be inserted, extended, lowered, plunged otherwisemoved until the tool tip contacts the bottom of the recess. Theadditional displacement of the tool tip beyond the top portion of thesurface where the tool tip first contacted the work surface indicatesthe depth of the recess. If the surface profile of the recess was ofinterest, the tool might be moved around the recess to multiple points.The tool can determine, at each of the multiple points, the depth. Thetool can record both the depth and lateral position of the tool (e.g.,x, y, and z coordinates, where x and y coordinates can refer to thelateral position and the z coordinate can refer to the depth). Thelateral motion could be accomplished automatically using a built-inpositioning stage, or performed manually by the user, or a combinationof both.

Another potential application could be to find the center position ofholes on a work surface. A tool with a conical tip can be fitted intothe device. The tool can then be positioned approximately (e.g., within5%, 10%, 15%, 20%, 25%, 30%, 50%, 75%, or 90% of the diameter of thehole) over the center of the hole, and plunged until the tip contactsthe circle of the hole. Because the tool tip can be conical, the tooltip can cause the tool to center over the hole. The tool can thendetermine the lateral position (e.g., x and y coordinates) using, forexample, a vision system to ascertain the position of the hole.

The tool can determine a thickness of a working surface or other pieceof material. Using the determined thickness of the working surface, thetool can automatically set cutting depths or update cutting paths thatmay be dependent on the material thickness (e.g., a box joint where thelength of the fingers are to correspond to the thickness of the matingmaterial). The tool can determine or measure the thickness of thematerial hang or place the tool or portion thereof over an edge of theworking surface or material, and then extend the tool tip until itcontacts the surface supporting the material. The depth the tool tipextends beyond the top of the work surface in order to contact thesurface supporting the working surface can indicate the thickness of theworking surface.

The tool can determine a location of the tool or tool tip relative to asurface of a working material using location markers that may includecontour trees, binary images, fiducial markers, or dominoes. The presentdisclosure facilitates directing and extracting dust away from a portionof the tool by generating airflow that directs the dust via one or morechannels in a portion of the tool. The present disclosure facilitatesdetermining a height of the tip of the tool using force sensors thatdetect a reduction in force when the tip of the tool touches thematerial.

With the determined information, the tool can be configured to guide aworking member of the tool to perform a task on a target material (e.g.,working surface). In some embodiments, a system may automatically guidea tool to perform the task. For example, in some embodiments, thepresent disclosure provides a handheld system that can identify thelocation of a tool, or a rig that contains a tool, relative to thematerial being worked. In some embodiments, the device may benon-handheld; e.g., the device may be on a movable platform such as aremote control platform, robotic platform, or another type of movableplatform that may or may not be controllable. The system may adjust thelocation of the tool (or provide instructions for the adjustment of thelocation of the tool) based on or responsive to the current location ofthe tool and a desired location corresponding to a design plan. In someembodiments, the system includes a handheld device with a workinginstrument capable of being operated by hand which can make precisionadjustments of the working instrument location based on spatial locationto provide an accurate path which the working instrument travels.

In some embodiments, systems and methods disclosed herein can include alocation detection system or perform one or more location detectiontechniques that can detect the current location or position of a tool ona target material accurately, robustly, or with low latency. Forexample, a video or sill image camera coupled to the tool andaccompanying control circuitry may be used to scan the surface of thematerial and process the scanned data or scanned image data to generatea digital map of the surface of the material in advance of performing atask on the material. When the tool is brought near the surface of thematerial during performance of a task on the material, the camera maytake a second image and compare the second image with the digital map todetect a location of the tool relative to the material.

In some embodiments, various location detection techniques may be usedincluding, e.g., integrating wireless position sensing technologies,such as RF, near field communication, Bluetooth, laser tracking andsensing, or other suitable methods for determining the position of thetool and facilitating guiding or adjusting the position of the tool toperform a task. In some embodiments, the system may include a hybridlocation detection system that employs two or more location detectiontechniques to determine the location of the tool. For example, eachlocation detection technique may include orthogonal strengths andweaknesses, but when combined, can detect a location with high accuracyand low latency. For example, a first location detection technique maybe high accuracy but low frequency (e.g., a sensor configured to obtaindata once per second that accurately determines the position but hashigh latency). The first location detection technique may be combinedwith a second location technique that includes a sensor that provideslocation information with high frequency and high accuracy but provideslimited information (e.g., an optical mouse sensor that is highfrequency and high accuracy but only provides dead reckoning includingdirection and speed of movement rather than the location of the tool ina global context). In an illustrative example, the hybrid locationsystem may use a camera to obtain an image to determine a position ofthe tool on the surface of the material accurately, and then use anoptical mouse sensor to track the change of the position until the nextframe of the image comes in. In this example, the second locationtechnique using the optical mouse sensor may not provide all locationtracking because integrating velocity to determine a position mayaccumulate error over time, or the device would not be able to determinea location if the device was picked up and put it down at a differentposition.

In some embodiments, to generate the map in advance of the cutting ordrawing operation, a user may sweep the surface of a material with acamera until the camera has obtained images of all, substantially all,or a portion of the surface of the material or desired portion thereof.The system may obtain these images and stitch the images together toproduce a cohesive map. Generating the digital map image and detectingthe location may include one or more image processing techniques,pattern recognition techniques, localization techniques, computer visiontechniques, for example. For example, the system may identify thatpoints A and B in a first image correspond to point C and D in a secondimage and accordingly stitch the two images. For example, on a woodsurface, the system may identify variations, bright spots, colorvariations, marks, fiduciary markers, binarized images, or wood grainsin the image and compare them with the digital map to determine alocation. In another example, the system may further use corners, sides,lighting patterns, or other signal capable of identifying a location.

The material can be marked to facilitate mapping of the surface of thematerial or detection of a position of the tool on or proximate to thematerial. For example, the surface of a material, such as metal orplastic, may not contain sufficient identifying marks to accuratelydetect location. Distinguishing marks or markers can be added to thematerial to facilitate location detection techniques such as patternrecognition or image processing. The markers can include any type ofmaterial, ink, tape, light, laser, carving, engraving, temperaturegradient, invisible ink (e.g., ink only visible under ultraviolet orother wavelengths of light) capable of facilitating a location detectiontechnique. In some embodiments, the marker includes a tape that can beapplied to at least a portion of the surface of the target material. Thetape may include symbols such as a unique barcode, design, pattern,colors, engravings, raised bumps or depressions, for example. In someembodiments, the marker may include a user randomly marking on thetarget material with a pen, pencil, ink, invisible ink, paint, crayons,or any other marking or writing instrument.

In addition to generating a digital image of the surface of thematerial, in some embodiments, the system may identify a cutting ordrawing design plan on the surface of the material. A design plan mayinclude any cutting or drawing a user of the system desires. Forexample, the design plan may include a freehand design, tracing,picture, image, design generated using computer-aided design (“CAD”)software, purchased design, or a purchased electronic design. The designplan can be a design of an object that the tool can create by performingan operation on the material, such as a design for a table that can becut from at least one piece of wood.

The system can incorporate the design plan with the map image orotherwise relate the design plan with a map of the surface of thematerial or overlay the design plan on the map image. In someembodiments, the design plan may be drawn on the surface of the materialbefore or after generating the initial map of the material (e.g., usinga special pen whose ink can be detected by the system using ultravioletor other wavelengths). If, for example, the surface of the materialincludes a design (e.g., a cutting design or drawing design) during theinitial mapping phase, the system may process the image to identify thedesign plan and include it in the digital map of the surface of thematerial. If the design is drawn or otherwise marked on the surface ofthe material after generating the initial map, the system may obtainimages of the material with the design by using the camera to rescan ortake new images of the material. If the design is drawn or otherwisemarked on the surface of the material before generating the initial map,the system may identify the design as a cutting or drawing design planor a user may indicate to the system that the identified design is acutting or drawing design plan.

In some embodiments, a digital design may be added to digital map of thesurface of the material without physically adding the design to thesurface of the material or otherwise marking the actual material with adesign. For example, the digital design may be generated on a computerand may include a CAD drawing or any other type of drawing (e.g., JPEG,BMP, or GIF). Using CAD software, for example, a user may modify the mapimage by adding the design plan. Any other suitable software may be usedto incorporate a design plan onto the map image or otherwise relate adesign plan with a map of the surface of the material (e.g., data thatindicates a location of the design plan used to facilitate theperformance of a task on a material). After registering the design onthe digital map or digital map image, the system may provide thecorresponding digital map data or digital image data with the designplan to the tool. In some embodiments, the system may display the mapimage with the design on a display device of the tool to facilitate auser performing a task on the material. In some embodiments, the toolmay perform the task in accordance with the design plan withoutdisplaying the design plan (e.g., the tool may automatically perform anaspect of the task or the tool may not include a display device).

During the cutting or drawing operation, a user may place the tool on ornear the surface of the material. Upon placing the tool on the surface,the camera may re-scan or take an image of a portion of the surface ofthe material. The image may correspond to a portion of the material thatis at a location different from the cutting or drawing tool. The systemmay determine the location of the tool relative to the surface of thematerial or the design plan by comparing identifying marks in the newimage with identifying marks in the map image generated in advance ofthe performance of the task on the material. The camera may be mountedor otherwise coupled to the tool such that image capturing aspect of thecamera (e.g., lens) is directed on the surface of the material at afixed and known vector from the cutting tool (e.g., drill bit). Byfocusing the camera away from the cutting tool, the system may obtainimages that are relatively clear of debris caused by cutting that mayobfuscate the markers used for detecting a location.

The system may compare the new images with the digital map of thesurface of the material to determine a precise location of the tool. Forexample, the portion of the digital map corresponding to the top rightcorner may include a set of identifying marks. Upon obtaining the newimage, the system may identify those same identifying marks anddetermine that those marks correspond to the top right corner of the mapimage. The system may then determine, based on the camera vector offset,the precise position of the cutting or drawing tool.

In some embodiments, the system may display, in real time, the preciseposition of the cutting or drawing tool on a display device (e.g., adisplay device of a tool or a remote display device communicativelycoupled to the system or tool). The system may indicate the position onthe display via an “X”, circle, dot, icon, or using any other indicationto signal a current position of the tool. In some embodiments, the toolmay overlay the indication of the current position on the design plan orcutting path (e.g., a predetermined path). In some embodiments, the toolmay overlay the indication of the current position on the map image. Insome embodiments, the tool may overlay the indication of the currentposition on the map image that includes an overlay of the design plan.

In some embodiments, the system may include a positioning system thatadjusts or moves the tool based on a detected location of the tool and adesign plan. In some embodiments, the system can use various locationdetection techniques to detect the location of the tool, and use variouspositioning techniques to move or adjust the location of the tool. Forexample, the system can include a hybrid positioning system thatincludes two or more positioning systems to position a tool. Upondetermining the location of the tool and a desired location for thetool, the first positioning system may be configured to move, adjust, orposition the tool over a relatively large range (e.g., move the tool toanywhere on the work area or surface of the material), but withrelatively low accuracy. The second positioning system may be configuredto move, adjust, or position the tool over a relatively short range(e.g., within a radius of 5 inches of the current location of the tool),but with high accuracy. In some embodiments, the first (e.g., coarse orrough) positioning system may include a human positioning a tool on thesurface of a material, and the second (e.g., fine or precise)positioning system may include positioning the tool using servo motors,stepper motors, actuation mechanisms, or eccentrics, for example. Thefirst positioning system can include non-human positioning systems suchas, e.g., robotic systems, remote control systems, or Global PositioningSystem (“GPS”) enabled devices.

For example, the first positioning system may include a long-range,low-accuracy positioning mechanism that is configured to move, adjust orcorrect the position of the tool based on the design plan. The secondpositioning system may include a short-range, high-accuracy positioningmechanism that can move, adjust or correct the position of the tool,within a maximum range, more precisely than the first positioningmechanism based on the design. In an illustrative and non-limitingexample, the first positioning system may include, e.g., a maximum rangethat includes the range of the entire work area (e.g., the areacomprising the surface of the material on which the task is to beperformed), and include an accuracy of +/−0.25″. The second positioningsystem may include, e.g., a maximum range of 0.5″, with an accuracy of+/−0.01″. The maximum ranges and accuracy of the first and secondpositioning systems may include other range and accuracy values thatfacilitate systems and methods of hybrid positioning. In variousembodiments, range and accuracy may refer to one-dimensional accuracy(e.g., along an X-axis), two-dimensional accuracy (e.g., X-Y axes) orthree-dimensional accuracy (e.g., X-Y-Z axes).

The first positioning system may be less accurate and include apositioning system where the maximum range is substantially greater thanthe maximum range of the second. For example, the first positioningsystem can move the tool from anywhere on the surface of the material towithin +/−0.25 inches of a desired location, while the secondpositioning system can be configured to move the tool up to 5 inchesfrom a current position, but with an accuracy of 0.01 inches. In someembodiments, the hybrid positioning system may include a plurality ofpositioning systems that are each configured to accurately determine alocation and then position the tool to within a certain distance rangesuch that, when the positioning systems are used together, the systemcan precisely determine a location and position or adjust the toolaccordingly. In some embodiments, the maximum range of each subsequentpositioning system may be equal to or greater than the accuracy of theprevious positioning system. In an illustrative example, a firstpositioning system may be able to position the tool on the surface ofthe material with, e.g., a maximum range corresponding to the size ofthe surface of the material, and with an accuracy of +/−1 inch. A secondpositioning system may be able to position the tool on the surface ofthe material within a maximum of range of 2 inches with an accuracy of+/−0.1 inch. A third positioning system may be able to position the toolanywhere within a maximum range of 0.2 inches with an accuracy of+/−0.01 inch. Therefore, in this example, by using all three positioningsystems together, the hybrid positioning system can precisely positionthe tool within a maximum range that includes the entire surface of thematerial or work area with an accuracy of +/−0.01 inch.

In some embodiments, the system may include automatic adjustment,guiding or error correction to facilitate performing a task inaccordance with a design plan. The system may use various types ofadjustment, guiding or correction mechanisms, including, e.g.,eccentrics, servomechanisms, stepper motors, control loops, feedbackloops, actuators, nut and bolt-type mechanisms. For example, the systemmay include eccentrics or servomotors coupled to a frame and the cuttingtool configured to adjust the position of the cutting tool relative tothe frame. Upon determining the current position of the cutting tool,the system may compare the current position with the desired position.The system may then guide the tool in accordance with the design plan.In some embodiments, when the system determines there is a discrepancybetween the current position and the desired position, or the currentposition or trajectory deviates from the design plan, the system mayadjust the cutting tool in accordance with the design plan. For example,the system may identify a cutting path or vector of the tool and thedesign plan and adjust the cutting tool such that the next cut is inaccordance with the design plan.

The system may utilize various automatic correction mechanisms. In someembodiments, the system may include eccentrics configured to adjust theposition of the cutting tool. For example, using two eccentrics, thesystem may adjust the position of the cutting tool in two dimensions.Eccentrics may include any circular widget rotating asymmetrically aboutan axis. For example, an eccentric may include a circle rotating aboutnon-central axis. The eccentrics may be coupled to the cutting tool andthe frame and be configured to adjust the position of the cutting toolrelative to the frame, which may adjust the position of the cutting toolrelative to the surface of the material. In some embodiments, the systemmay utilize a screw with a nut to change rotational motion to lineardisplacement to correct or adjust tool positioning.

In some embodiments, the system may include orientation control based onthe type of cutting tool. For example, if the cutting tool is a sabersaw that cannot be adjusted perpendicularly, the system may adjust theorientation or angle of the saber saw in accordance with a design plan.They system may include actuators configured to adjust the tilt or angleof the saw.

The system can control the z-axis of the cutting or drawing tool. Thesystem can determine the position of the tip of the cutting toolrelative to the work surface. By controlling the z-axis (e.g., an axisthat is substantially orthogonal to a surface of the material; an axisthat is vertical; an axis that is parallel to an axis along which theworking member is lowered or raised to or from the surface of theworking member or cutting tool) of the cutting or drawing tool, thesystem may start and stop cutting or drawing in accordance with a designplan. For example, if the cutting tool is beyond a correctable distanceaway from the design plan (e.g., outside the radius of automaticcompensation), the system may stop the cutting by adjusting the z-axisposition of the cutting tool (e.g., lifting the drill bit off the wood).When the user brings the cutting tool back to within the radius ofautomatic adjustment, the system may automatically adjust the z-axisposition of the cutting tool such that cutting commences again (e.g.,lowers the drill bit into the wood). The radius or range of compensationmay correspond to a positioning system of the localization system. Forexample, if the localization system includes a hybrid positioning systemthat includes a large range and short range positioning system, theradius of compensation may correspond to the short range positioningsystem. In some embodiments, controlling the z-axis position of the toolmay facilitate making 2.5 dimension designs. For example, a design planmay indicate z-axis information corresponding to the surface of thematerial. Thus, the system can use a determined z-axis position of theworking member or cutting tool or tip thereof to control a motor to movethe working member to a second location or position (e.g., x, y, or zaxis position).

In some embodiments, the system may indicate to the user that thecutting tool is on the design path (e.g., a predetermined path) orwithin the range of compensation such that the system may correct theposition of the cutting tool. In some embodiments, the system mayindicate to the user that the cutting is not on the design path or notwithin the range of compensation. The system may further indicate to theuser to correct the position of the cutting tool or a direction in whichto move the cutting tool to bring it on the design path or within therange of compensation. The system may provide one or more indicationvisually via the display device, using light emitting diodes or otherlight sources, audio signal, beeps, chirps, or vibrations. In someembodiments, an indication that the tool is deviating from the designpath beyond an acceptable range may include automatically shutting offthe cutting machine or adjusting the z-axis of the cutting or drawingtool such that it stops performing a task on the material. In someembodiments, the system may indicate the design path on the material ofthe surface itself by, e.g., shining a beam of light indicating to theuser where the design path is and where to proceed. For example, upondetermining the error, the system may shine a beam indicating to theuser how much to adjust to the tool in order to bring the position ofthe tool to within the range of automatic compensation or on the designpath.

In some embodiments, a plurality of cutting or drawing tools may be usedwith the system including, e.g., saber saw, jig saw, router, or drill.The system may be configured such that users may use various aspects ofthe present disclosure with various cutting or drawing tools withoutmaking any adjustments to the tool or minor/temporary adjustments. Forexample, the system may include a frame, camera, display device, andcomputing device. The frame may be configured such that a cutting toolmay be placed in the frame. The camera may be coupled to the frame ormay be attached to the cutting tool. Upon placing the camera, the systemmay automatically or manually be calibrated such that the system obtainsthe vector offset between the camera and the cutting or drawing tool(e.g., the drill bit).

In some embodiments, the system may include a freestanding deviceconfigured to perform mapping and localization functions and indicate toa user the current position of the device. In some embodiments, thefreestanding device may be attached to a cutting tool or drawing tool.In some embodiments, the freestanding device may not provide automaticcorrection functionality. In some embodiments, the freestanding devicemay include a display or a camera. In some embodiments, the freestandingdevice may determine a design path and detect when the tool is off thedesign path. The freestanding device may indicate the error by, forexample, the display, shining a light on the surface of the material,audio signals, or voice narration.

Referring to FIG. 1, an illustrative example of an embodiment of anapparatus for guiding tools to perform a task is shown. In someembodiments, the device includes a frame and a tool (e.g., a router inthe example of FIG. 1) mounted within the frame. The frame may bepositioned manually by the user. The device can adjust the position ofthe tool within the frame to guide or adjust the tool in accordance witha design plan or to correct for error in the user's coarse positioning.The device may also include a display and be configured to map thetarget material and display it on the display. In some embodiments,markers on the target material (e.g., stickers) may facilitategenerating a map of the target material by providing differentiatingfeatures. The device may obtain a design or plan by downloading it froman online store. The device may display a map of the target materialwith the design that indicates the desired cutting pattern.

Referring to FIG. 2, an illustrative example of an apparatus forautomatically guiding tools following a target path area and performinga task according to a planned design is shown. In some embodiments, tofollow a complex path, the user of the device may need to only move theframe in a rough approximation of the path. In this example, the dottedline shows the path that the tool would take if its position were notadjusted; the solid line is its actual path, e.g., an outline of thesoutheastern United States. In this example, the user can grip the frameand guide the tool generally along the dashed line, and the tool canself-adjust to cut along the solid line. In some embodiments, the deviceautomatically adjusts the drill bit or other cutting tool based on theposition of the cutting tool (e.g., one or more of an x-axis position,y-axis position, or z-axis position) and the desired position of thecutting tool. The x-axis and y-axis can intersect to form an x-y planethat is substantially parallel (e.g., within 45 degrees) to the surfaceof the material, while the z-axis is substantially perpendicular (e.g.,45 degrees of being perpendicular) or orthogonal to the horizontal planeformed by the x-y axis. In some embodiments, the user of the device maymove the device along the dotted line 1210 in FIG. 2 (or the path 406 ofFIG. 23), while the device automatically adjusts the cutting tool (e.g.,an x, y or z position) in accordance with the desired design plan, suchas the design plan 1205 of FIG. 2 For example, the device may identifyor detect the current position of the cutting tool relative to thetarget surface with the design. The device may then compare the currentposition with the desired position of a design or map and adjust thecutting tool. For example, if the working member or cutting tool tip isdetermined to be 1 inch above the surface of the material, the systemcan determine to lower the cutting member tip to contact the surface ofthe material. In another example, if the design indicates to drill awhole 0.5 inches deep into the material, then the system can determinethe z-axis position of the tip and insert the tip 0.5 inches into thematerial based on the determined z-axis position. For example, thesystem can instruct a motor to extend the working member or cutting tool0.5 inches beyond the surface of the material.

Referring to FIG. 3, an illustrative block diagram of an embodiment of asystem for automatically guiding tools is shown. In some embodiments,the system 680 includes a smart device 681. The smart device 681 mayinclude at least one central processing unit (“CPU”) or processor 683,and may include software code 685 that performs one or more processes,at least on memory 687, or at least one display 689. The smart device681 may include a self-contained unit or the smart device 681 mayinclude components that are not self-contained or separated. Forexample, the display 689 may be tethered to the smart device 681 orintegrated into the housing of the smart device 681. In someembodiments, the smart device 681 may be integrated as part of thesystem 680 so that the system is a self-contained portable unit.

In various embodiments, the system 680 can include one or more sensorsto facilitate determining a location of the tool (e.g., IR, lasers,ultrasonic range finding, etc.). For example, and in some embodiments,the system 680 can include a camera 682 that can be used in combinationwith the smart device 681 to build a map 684 of the material to beworked on. The camera 682 may be coupled or attached to any tool 699 toprovide positioning for that tool 699. In some embodiments, the camera682 is coupled with a display 689 and CPU 683. For example, the camera682 may be part of a computer or smart device 681 that can be attachedor coupled to any tool 699. A software application or code 685 can beinstalled on a mobile smartphone and can utilize the camera, CPU,memory, and display of the smartphone. In some embodiments, one or moreaspect of the software or processing may be performed by a fieldprogrammable array device (“FPGA”) or a digital signal processor(“DSP”).

In some embodiments, the camera 682 can take images with a high-framerate. For example, the camera can scan the surface of the material toobtain scanned data or scanned image data. In some embodiments, thecamera may scan the surface of the material and a processor can processthe scan to generate scanned data that indicates a map of the surface ofthe material. This may facilitate location functions or mappingfunctions disclosed herein. The camera 682 can also take images with arelatively low-frame rate and the camera 682 can be coupled with one ormore optical sensors (e.g., sensors in optical computer mice). Theoptical sensors may provide low-latency dead reckoning information.These optical sensors may be used in conjunction with the camera 682.For example, the camera 682 may provide accurate global positioninformation a few times a second and appreciable lag, and the opticalsensors may be used to provide dead-reckoning information with low lagthat fills in the time since the last image was taken. In someembodiments, accelerometers may be used for dead-reckoning. The system100 may use multiple cameras to increase the accuracy or range ofcoverage when scanning, or to provide depth information.

In some embodiments, the system 100 is configured to build, generate orotherwise receive a map 684. In some embodiments, the map 684 may bebuilt using computer vision (“CV”) or sensors techniques. For example, aCV technique may be used to build a photo mosaic. A photo mosaic processmay include taking multiple photographs of different parts of the sameobject and stitching at least two of the photographs together to make atleast one overall image covering the entire object.

In some embodiments, the system 680 or processor may be configured toevaluate the scanned data using a technique that includes simultaneouslocalization and mapping (“SLAM”). SLAM may include using a sensor thatis communicatively coupled with a processor 683 and related software 685to build a map 684 of the material being worked on (or “targetmaterial”) while determining (e.g., simultaneously) the location of thetool 699 relative to the map 684. For example, after building at least aportion of the map, a camera 682 may capture images of the materialbeing worked. The images may be fed to and processed by the smart device681 to determine the location of the tool 699 or rig. The system 680 mayanalyze the captured images based on the map 684 to determine thelocation (e.g., geo location) of the camera 681 relative to thematerial. Upon determining the location of the camera 682, in someembodiments, the system 680 may identify that the location of the rig isa known or determinable offset from the position of the camera 682,which may be rigidly attached to the rig.

Various embodiments may use various other location processing anddetermining technologies including, e.g., integrating wireless positionsensing technologies, such as RF, near field communication, Bluetooth,laser tracking and sensing, or other suitable methods for determiningthe position of the tool 699 on top of the work piece. For example,ultrasonic, IR range finding, or lasers can be used to detect thelocation of the tool relative to a work area or surface of a material.The detected location of the tool can be provided to any other componentof the system 680 to facilitate guiding or adjusting the position of thetool in accordance with an embodiment.

In some embodiments, the system 680 may be configured to compute thelocation of the tool 699 relative to the rig using the currentorientations of the motor shafts. For example, the system 680 mayidentify the orientations of the motor shafts by homing them and thentracking one or more acts taken since the homing process. In someembodiments, the system 680 may use encoders could be used instead ofhoming as the encoders would be able to tell the orientations of theshafts directly. Through the offsets and calculations, the system 680can identify the location of the tool 699 or rig relative to thematerial being worked on. The captured images that can be analyzedagainst the map 684 may include, e.g., characteristics of the materialsuch as wood grains and deformations or may include markers placed onthe material. Various aspects of the mapping and location technologywill be described in more detail below.

In some embodiments, the system 680 may receive a design 686 ortemplate. For example, the smart device 681 may be configured to receivethe design 686 or template from a user of the system 680. The smartdevice 681 may include or have access to various input/output devicesconfigured to receive the design 686. In some embodiments, the system680 may receive the design 686 via a network. In some embodiments, theuser or system 680 may modify or adjust the design 686 based on the map684. For example, a user may adjust the size of the design 686 relativeto the map 684 of the material in order to generate a desired workingpath on the material being worked on. In some embodiments, the system680 may automatically adjust or optimize the size of the design based onthe dimensions of the material.

The network may include computer networks such as the Internet, local,metro, or wide area networks, intranets, and other communicationnetworks such as mobile telephone networks. The network can be used toaccess web pages, online stores, computers or data of a retail storethat can be displayed on or used by at least one user device, system680, or system 100, such as, e.g., a laptop, desktop, tablet, personaldigital assistants, smart phones, or portable computers.

The system 680 may be configured to create, capture, or load designs 686in a plurality of ways. In some embodiments, designs may be downloadedor otherwise obtained. For example, a user may generate a design on acomputing device and transfer or otherwise convey the design to thesystem 680. In another example, the system 680 may receive the designfrom a third party entity. For example, a user may purchase a designonline via a network and upload the design to the smart device orcomputer 681. In some embodiments, the system 680 may facilitatecapturing a map of the surface and also of the design 686 on thatsurface. This may facilitate setting up the system 680 to follow aspecific line or to show the user an image of the surface of thematerial underneath a large tool that obstructs sight, or to show thesurface with a drawn plan in a pristine state before it is covered withdebris or the surface on which the plan is drawn is cut away. In someembodiments, the design 686 could be designed, altered, or manipulatedfrom its original form on the device 681 through a menu driven interfaceallowing the user to input distances, angles, and shapes or to free handa drawing on a touch sensitive pad or display.

In some embodiments, while a user moves the system or rig 680 along thetarget material, the smart device 681 processes the captured images fromthe camera 682, determines the location of the rig 680, or provides adesired path to the user on display 689. Once the user has placed therig 680 close to the desired path, the rig or system 680 mayautomatically adjust the position of the tool 699 to achieve the desiredworking path in accordance with the loaded design 686. The term “rig”and “system” may be used interchangeably as described herein. In someimplementations, the rig includes the physical device and itsattachments, and the system includes the physical device, itsattachments, and related technology and software code embedded orincluded in some of the physical elements.

In some embodiments, the system 100 builds the map 684 based on imagescaptured by the camera along an arbitrary path of the target materialuntil the entire area of interest has been covered. For example, a usermay sweep the camera 300 in an arbitrary path over the surface of thematerial until the entire area of interest has been covered. In someembodiments, the system 100 can be configured such that the camera 682can be removed from the rig 100 to sweep or pass over an area of thematerial. The system 100 may stitch together the images obtained by thecamera 682. For example, the system 100 may use an image mosaic softwarecode 685 to form a cohesive map 684 of the area of interest of thesurface of the material. The system 100 may store the map 684 in memory687. Upon receiving an image taken by the camera 682 of mapped material,the system 100 can compare the image with the map 684 held in memory 687and may further determine a position and orientation. For example, thesystem 100 may determine, based on the comparison, the position of thetool, drill, system, cutting member, stage, or rig.

In some embodiments, the system 680 may allow a user to create and loada design 686 after the map 684 has been assembled. For example, afterthe map 684 has been assembled on the smart device 681 (such as acomputer), the user may create a design 686 on the computer by plottingit directly on the generated map 684. For example, the user may markpositions on a piece of wood where a drill hole is desired. Thetechniques and features of the software code 685 (include computer aideddesign and manufacturing) can be employed to create a design withaccurate measurements. Then, when the user returns to the material, theposition of the camera 682 on the map 684 may be displayed on a screenor display 689 to the user, with the design plan 686 overlaid on the map684. For example, the system 680 can display on the display device a mapimage overlaid with an indication of a position (e.g., position of thesensor, device, cutting tool or drawing tool) relative to the surface ofthe material. In some embodiments, the system 680 may identify the geolocation of the tool relative to the map. For example, the camera 682may be attached to a drill and used to determine the position of thedrill exactly relative to target drill locations specified in the design686, facilitating the user to line up the drill more precisely.

In some embodiments, the system 680 is configured to build the map andtrack the camera's position using visual features of the targetmaterial. In some embodiments, the software 685 includes instructions tobuild the map and track the camera's position using visible features ofthe material such as grains, imperfections, or marks. The targetmaterial may be altered to facilitate mapping and tracking functions.For example, solid colored plastic may be too undifferentiated for thesystem 680 to effectively map or track. Therefore, a user may, e.g.,alter the material surface in some way to add features that can betracked. In another example, the system 680 may instruct a marker toarbitrarily add features that can be tracked. For example, features thatmay be added may include ink to the material that is typicallyinvisible, but which can be seen either in a nonvisible spectrum or inthe visible spectrum when UV or other light is applied, allowing thecamera to track the pattern of the invisible ink while not showing anyvisible markings once the work is done. In some embodiments, the usermay apply stickers with markers which can later be removed. Featurescould also be projected onto the material such as with a projector. Or,if the user will later paint over the material or for other reasons doesnot care about the appearance of the material, the user could simplymark up the material with a pencil or marker.

In some embodiments, the marker tape or stickers may include a uniquesequence of barcodes over the entire length of the tape. In someembodiments, the marker tape may be thin such that the device may passover the marker tape without getting stuck or disturbed. In someembodiments, the tape may be designed and constructed such that it willstay down as the device moves over the tape, but can also be easilytaken off upon completion of the project. Marker tape materials mayinclude, for example, vinyl or any other suitable material.

In cases where the camera cannot track the material, or cannot do soaccurately enough, or the material is unsuitable for tracking (e.g. dueto an uneven surface), or any other reason that prevents the cameratracking the surface directly, the camera may track other markers off ofthe material. For example, the user may put walls above, below, oraround the sides of the material being worked on that have specificfeatures or marks. The features or marks on the surrounding surfaces mayenable the camera to determine its position on or relative to thematerial. In various embodiments, different types of positioningtechnology or devices may be used to locate the tool 699 or stage 690,possibly in conjunction with a camera 682 that is used mainly forrecording the visual appearance of the material without needing toperform the tracking function. Positioning technology may include, e.g.,ultrasonic, IR range finding, or lasers, for example.

The system 680 can adjust the precise location of the tool 699 byadjusting the geo location of the stage 690 or a moveable platform towhich the tool 699 is attached. The stage 690 may be connected to aneccentric coupled to a motor shaft. As the motor shaft moves in acircular path the eccentric moves the stage 690 in complex arcs andpaths. A pivot 694 may be connected to the stage and is also connectedto an eccentric coupled to a second or pivot motor shaft. The pivot 694may be configured to pull or push the stage 690 to achieve controlledmovement of the stage within a 360 degree range. By controlling therotation of the eccentrics, the system 680 may position the stage inalmost any XY position in the range.

In some embodiments, the system 680 uses a reference lookup table tofacilitate guiding the tool. For example, a reference look table mayinclude motor coordinates related to desired stage positions. In someembodiments, the system 680 may compute calculations that can be used toadjust the motors that move the stage 690 and the cutting bit of thetool 699 connected to the stage 690 to the desired location. In someembodiments, the system 680 may move the tool 699 360 degrees in a twodimensional plane by positioning the stage 690 and pivot 694. Forexample, the cutting instrument of the tool can be moved anywhere withinthe 360 degree window of the target range 408.

In some embodiments, electric motors may move, position or adjust thestage 690 and pivot 694. A stage motor controller 691 may control thestage motor 210. A pivot motor controller 695 may control the pivotmotor 220. The stage motor controller 691 and pivot motor controller 695may receive information that includes the desired location orcoordinates from the smart device 681. Based on the receivedinformation, the stage motor controller 691 and pivot motor controllermay 695 activate and control their respective motors 210, 220 to placethe stage 690 and the pivot 694 in the proper or desired position,thereby positioning the tool in the desired geo location.

In some embodiments, the smart device 681 may communicate with, receiveinformation from, and control the tool 699. For example, the smartdevice 681 may send instructions to power on or off or increase orreduce speed. In some embodiments, the instructions may signal when toengage the target material by, e.g., adjusting the depth of the tool 699when the user is close enough to or near the desired path on thematerial.

FIG. 4 provides an illustrative flow chart of an embodiment of a method600 for performing a task on a target material. For example, the method600 may facilitate cutting a working surface using a router basedembodiment. In some embodiments, at act 602 the user may find or createa design they want to cut out of a material. In some embodiments, thetask may include a plurality of tasks (e.g., a first task and a secondtask that may be a subset of the entire task). For example, the task ofcutting the design out of the material may comprise a first task ofcutting a first portion of the design and a second task of cutting asecond portion of the design. In some embodiments, the first and secondtask may be substantially similar (e.g., same type of cutting or drawingtool), while in other embodiments the first and second task may differ(e.g., different drill bit or drawing tool, different type of cuttingtool, different user device, different area of the material, etc.).

Prior to or subsequent to identifying the design plan, the user may mapthe surface of the material or sheet of material. If the material hasenough markings the user may use the material itself. However, in act604, if the material has a flat surface or limited markings the user canplace markers on the material. Markers may include, e.g., printer markerstickers or other type of suitable indicia capable of being readilyidentified.

In some embodiments, at act 606, a sensor may scan the material toobtain scanned data. For example, a camera scans the material and thevarious markers to create the map. The CPU may process the imagescaptured by the sensor or the camera and generate the map or scanneddata. The size and shape of the map can be appropriately manipulated toa preferred configuration. In some embodiments, at act 608, the designis registered or otherwise related to the map to create a cutting plan.

In some embodiments, at act 610, the cutting tool is prepared to performthe task. For example, a user may load, adjust, or secure the bit, mountit to the rig and turn the router on. In some embodiments, the systemmay turn on the router via a software initiated process in response toone or more parameters, including, e.g., motion sensing of a movement ofthe rig 100 in a particular direction by the user.

In some embodiments, at act 612, the system may receive varioussettings. For example, the user may set the width of the bit of thecutting tool, the range (e.g., area) of the tool's desired rangecorrection, the size of the cross-hair, or the speed of the cuttingtool. Thereafter, instructions may be provided to the software to beginthe task.

In some embodiments, at act 614, the rig is placed adjacent to thedesired path so that the system can automatically adjust the position ofthe tool into a starting adjustment range position along the desiredpath. The user may then follow the constant speed strategy as describedherein, for example with regards to FIG. 3. In some embodiments, oncethe tool has advanced fully around the plan (act 616) the user canremove the device and work product from the material.

FIG. 5 shows an illustrative flow chart of an embodiment of a method 650for the constant speed strategy. The process in FIG. 3 assumes the useralready has the router attached to the rig and has mapped their materialand loaded up their design. In some embodiments, at act 651, the userstarts the process to cut the material. The process can include movingthe tool to a spot within the range of plan or path on the material (act653). For example, a user may move the tool or the tool may be remotelycontrolled.

In some embodiments, the process includes determining, based on thelocation of the tool, whether there is a point on the plan within theadjustment range of the rig (act 655). In the event that there is nopoint within range, the process may include sending a notification(e.g., via the display, audio, vibration, light, or LED) and waitinguntil the user moves the device within the adjustment range (act 657).

In some embodiments, if there is a point within the adjustment range,the process includes, at act 659, setting the point on the plan nearestto the tool as the target point. In some embodiments, the process mayinclude moving the tool to the target point and cuts the material (act661).

In some embodiments, the process includes creating a second target bydetermining if a new target is within the adjust range (act 663). Ifthere is a second target, the process may include setting the secondtarget point as the new target (act 665). The device may continue tomove in a clockwise direction, cutting from the old target point to thenew target point. In some embodiments, the process may includeidentifying the next target point within the adjustment range (act 663)while the tool or router is cutting from the old target point to the newtarget point. For example, the determination of an optimum or desiredsecond target may be continuous, and based on the image, or variousimages, detected from the camera and processed by the system.

If there is no target point within range, in some embodiments, theprocess includes clearing the target point (act 667) and starting at act655 to determine whether there is a point on the plan within theadjustment range. In some embodiments, this process continues until thetool has gone through the all or part of the plan in a particulardirection, such as a clockwise direction.

In some embodiments, the mapping phase may be bypassed if the materialsize is greater than the design. For example, the user may determine astarting point that corresponds with a region on the design (i.e. thetop right corner) and the system 800 may start painting the image.

The embodiments discussed herein so far have focused on rigs thataccommodate a tool being attached to a stage and the stage is moved orcontrolled by one or more motors. The linear design depicts a routermoved by a motor where the router is connected to a linear stage. Insuch instances, the router is attached or mounted as a separate unit.However, the system can be designed as one unit where the stage, motorsmoving the stage, controllers, and all within the same housing andwithin the same power system as the housing and power of the tool. Byway of example, the router housing would be enlarged to fit the stageand motors and might include a display integrated into the housing.Through such an embodiment, the form factor might be improved to looklike a one piece tool.

The embodiments presented here are not meant to be exhaustive. Otherembodiments using the concepts described herein are possible. Inaddition, the components in these embodiments may be implemented in avariety of different ways. For example, a linear stage, or a hingejoint, or an electromagnetic slide, or another positioning mechanism maybe used to adjust a tool or the stage the tool is on in reaction to itsdetected position and its intended position.

By way of example, the systems and methods described herein can be usedwith drills, nail guns, and other tools that operate at a fixedposition. In such embodiments, the tool and software could be modifiedsuch that the plan includes one or more target points instead of a fulldesign. The device could be moved by the user such that a targetposition is within the adjustment range. The software could then movethe tool to the correct target position. The user could then use thetool to drill a hole, drive in a nail, or perform other operations.

In some embodiments, the tools can facilitate performing a task withoutproviding automatic adjustment. For example, the stage, pivot, motors,and eccentrics could be removed. The tool could be attached to the lowerstage housing. The software could be modified such that the planincludes one or more target points. The user could move the device suchthat the tool is directly over the target position. The user could usethe location feedback provided on the display to perform accuratepositioning.

In some embodiments, the present disclosure facilitates guiding orpositioning a jigsaw. A jigsaw blade may be rotated and moved in thedirection of the blade, but not moved perpendicular to the blade or itwill snap. The present disclosure may include a rotating stage that canbe placed on top of the positioning stage. The jigsaw may be attached tothis rotating stage. The software may be modified to make the jigsawfollow the plan and rotate to the correct orientation, and made toensure that the jigsaw was not moved perpendicular to the blade. In someembodiments, a saber saw may take the place of the jigsaw to achieve thesame effect. The cutting implement may be steered by rotating therotating stage, and the cutting implement could be moved along thedirection of cutting by moving the positioning stage.

In some embodiments, the system may support rotation and not supporttranslation. For example, the system may automatically orient the bladein a scrolling jigsaw (e.g., a jigsaw with a blade that can be rotatedindependently of the body). In this embodiment, the software may steerthe blade to aim it at the correct course and the user may beresponsible for controlling its position.

In some embodiments, the system may position a scroll saw. For example,the camera may be coupled to the scroll saw, and the user may move thematerial. The upper and lower arms of the scroll saw may be mechanizedsuch that they can move independently by computer control. The user maythen move the material such that the plan lay within the adjustmentrange of the scroll saw, and the software would adjust the scroll saw tofollow the plan. In some embodiments, the upper and lower arms could bemoved to the same position, or moved independently to make cuts that arenot perpendicular to the material.

In some embodiments, the position correcting device can be mounted to amobile platform. For example, the device may be placed on material andleft to drive itself around. The device can also be used in analternative embodiment in which two mobile platforms stretch a cuttingblade or wire between them. For example, each platform may be controlledindependently, allowing the cutting line to be moved arbitrarily in 3D,for example to cut foam.

In some embodiments, the system may be coupled or otherwise attached tovehicles or working equipment such as a dozer in which theposition-correcting mechanism is mounted on the vehicle. For example,some embodiments of the hybrid positioning system may include a vehiclecomprising a first position-correcting system that is accurate to withina first range and a second position-correcting system that is accurateto a second range that is more precise than the first range. The vehiclemay be driven over a sheet of material such as a steel plate lying onthe ground, and a cutting tool such as a plasma cutter could be used tocut the material. In some embodiments, the present disclosure mayfacilitate a plotting device or painting device, for example to lay outlines on a football field or mark a construction site. The vehicle, forexample, may include an industrial vehicle such as a forklift typevehicle configured to include a cutter or other tool, a camera, andcontrol circuitry described herein to determine location of the vehicle(or the tool) on the material, identify where to cut or mark thematerial, and adjust the tool to cur or mark the material in theappropriate location.

FIG. 6 is a block diagram of a computer system 600 in accordance with anillustrative implementation. The computer system 600 can be used toimplement system 680. The computing system 600 includes a bus 605 orother communication component for communicating information and aprocessor 610 or processing circuit coupled to the bus 605 forprocessing information. The computing system 600 can also include one ormore processors 610 or processing circuits coupled to the bus forprocessing information. The computing system 600 also includes mainmemory 615, such as a random access memory (RAM) or other dynamicstorage device, coupled to the bus 605 for storing information, andinstructions to be executed by the processor 610. Main memory 615 canalso be used for storing position information, temporary variables, orother intermediate information during execution of instructions by theprocessor 610. The computing system 600 may further include a read onlymemory (ROM) 1220 or other static storage device coupled to the bus 605for storing static information and instructions for the processor 610. Astorage device 625, such as a solid state device, magnetic disk oroptical disk, is coupled to the bus 605 for persistently storinginformation and instructions.

The computing system 600 may be coupled via the bus 605 to a display635, such as a liquid crystal display, or active matrix display, fordisplaying information to a user. An input device 630, such as akeyboard including alphanumeric and other keys, may be coupled to thebus 605 for communicating information and command selections to theprocessor 610. In another implementation, the input device 630 has atouch screen display 635. The input device 630 can include a cursorcontrol, such as a mouse, a trackball, or cursor direction keys, forcommunicating direction information and command selections to theprocessor 610 and for controlling cursor movement on the display 635.

According to various implementations, the processes described herein canbe implemented by the computing system 600 in response to the processor610 executing an arrangement of instructions contained in main memory615. Such instructions can be read into main memory 615 from anothercomputer-readable medium, such as the storage device 625. Execution ofthe arrangement of instructions contained in main memory 615 causes thecomputing system 600 to perform the illustrative processes describedherein. One or more processors in a multi-processing arrangement mayalso be employed to execute the instructions contained in main memory615. In alternative implementations, hard-wired circuitry may be used inplace of or in combination with software instructions to effectillustrative implementations. Thus, implementations are not limited toany specific combination of hardware circuitry and software.

Although an example computing system has been described in FIG. 6,implementations of the subject matter and the functional operationsdescribed in this specification can be implemented in other types ofdigital electronic circuitry, or in computer software, firmware, orhardware, including the structures disclosed in this specification andtheir structural equivalents, or in combinations of one or more of them.

Implementations of the subject matter and the operations described inthis specification can be implemented in digital electronic circuitry,or in computer software, firmware, or hardware, including the structuresdisclosed in this specification and their structural equivalents, or incombinations of one or more of them. The subject matter described inthis specification can be implemented as one or more computer programs,i.e., one or more circuits of computer program instructions, encoded onone or more computer storage media for execution by, or to control theoperation of, data processing apparatus. Alternatively or in addition,the program instructions can be encoded on an artificially generatedpropagated signal, e.g., a machine-generated electrical, optical, orelectromagnetic signal that is generated to encode information fortransmission to suitable receiver apparatus for execution by a dataprocessing apparatus. A computer storage medium can be, or be includedin, a computer-readable storage device, a computer-readable storagesubstrate, a random or serial access memory array or device, or acombination of one or more of them. Moreover, while a computer storagemedium is not a propagated signal, a computer storage medium can be asource or destination of computer program instructions encoded in anartificially generated propagated signal. The computer storage mediumcan also be, or be included in, one or more separate components or media(e.g., multiple CDs, disks, or other storage devices). Accordingly, thecomputer storage medium is both tangible and non-transitory.

The operations described in this specification can be performed by adata processing apparatus on data stored on one or morecomputer-readable storage devices or received from other sources.

The term “data processing apparatus” or “computing device” encompassesvarious apparatuses, devices, and machines for processing data,including by way of example a programmable processor, a computer, asystem on a chip, or multiple ones, or combinations of the foregoing.The apparatus can include special purpose logic circuitry, e.g., an FPGA(field programmable gate array) or an ASIC (application specificintegrated circuit). The apparatus can also include, in addition tohardware, code that creates an execution environment for the computerprogram in question, e.g., code that constitutes processor firmware, aprotocol stack, a database management system, an operating system, across-platform runtime environment, a virtual machine, or a combinationof one or more of them. The apparatus and execution environment canrealize various different computing model infrastructures, such as webservices, distributed computing and grid computing infrastructures.

A computer program (also known as a program, software, softwareapplication, script, or code) can be written in any form of programminglanguage, including compiled or interpreted languages, declarative orprocedural languages, and it can be deployed in any form, including as astand alone program or as a circuit, component, subroutine, object, orother unit suitable for use in a computing environment. A computerprogram may, but need not, correspond to a file in a file system. Aprogram can be stored in a portion of a file that holds other programsor data (e.g., one or more scripts stored in a markup languagedocument), in a single file dedicated to the program in question, or inmultiple coordinated files (e.g., files that store one or more circuits,sub programs, or portions of code). A computer program can be deployedto be executed on one computer or on multiple computers that are locatedat one site or distributed across multiple sites and interconnected by acommunication network.

Processors suitable for the execution of a computer program include, byway of example, both general and special purpose microprocessors, andany one or more processors of any kind of digital computer. Generally, aprocessor will receive instructions and data from a read only memory ora random access memory or both. The essential elements of a computer area processor for performing actions in accordance with instructions andone or more memory devices for storing instructions and data. Generally,a computer will also include, or be operatively coupled to receive datafrom or transfer data to, or both, one or more mass storage devices forstoring data, e.g., magnetic, magneto optical disks, or optical disks.However, a computer need not have such devices. Moreover, a computer canbe embedded in another device, e.g., a mobile telephone, a personaldigital assistant (PDA), a mobile audio or video player, a game console,a Global Positioning System (GPS) receiver, or a portable storage device(e.g., a universal serial bus (USB) flash drive), to name just a few.Devices suitable for storing computer program instructions and datainclude all forms of non volatile memory, media and memory devices,including by way of example semiconductor memory devices, e.g., EPROM,EEPROM, and flash memory devices; magnetic disks, e.g., internal harddisks or removable disks; magneto optical disks, and CD ROM and DVD-ROMdisks. The processor and the memory can be supplemented by, orincorporated in, special purpose logic circuitry.

To provide for interaction with a user, implementations of the subjectmatter described in this specification can be implemented on a computerhaving a display device, e.g., a CRT (cathode ray tube) or LCD (liquidcrystal display) monitor, for displaying information to the user and akeyboard and a pointing device, e.g., a mouse or a trackball, by whichthe user can provide input to the computer. Other kinds of devices canbe used to provide for interaction with a user as well; for example,feedback provided to the user can be any form of sensory feedback, e.g.,visual feedback, auditory feedback, or tactile feedback; and input fromthe user can be received in any form, including acoustic, speech, ortactile input.

Referring to FIG. 7A, an illustrative example of an embodiment of adesign plan and marking material 702 is shown. Placing marking material704 may facilitate mapping the target material. For example, the targetmaterial may not contain sufficient differentiating marks. Addingdifferentiating marks (e.g., stickers, ink, pencil) to the targetmaterial may facilitate the system 680 in mapping the target materialand tracking the positioning of the cutting tool during the cuttingprocess. In this example, the design plan is in the shape of a country.The marking material may be placed on the surface of the target materialto facilitate mapping the target material and tracking the position andadjusting the position in accordance with the design.

Referring to FIG. 7B, an illustrative example of an embodiment oflocating markers 706 is shown. The locating markers 706 may be includedas part of the design plan or may refer to a type of marking material702 used to form the design plan. The locating markers 706 may be placedon the target material and used by the system 680 to map the targetmaterial and track a position of the cutting tool relative to thesurface of the material.

Locating markers 706 can be designed, constructed or configured suchthat they are easy for the system 680 to detect and read (e.g., viacamera or sensor 682). For example, the locating markers 706 may includedominoes that represent a binarized image. A binarized image may includean image with two values, such as an image with two colors. In someembodiments, the two colors may be selected such a first color of thetwo colors contrast with a second color of the two colors. For example,the two colors may include white and black, red and white, orange andblue, green and purple, etc. Dominoes-based locating markers 706 may beeasy and fast to read by system 680. By using locating markers 706 witha predetermined number of features (e.g., blobs 710), the locatingmarkers 706 can be read from a binarized image contour tree fast.Further, each domino can include a number, which facilitates trackingmultiple dominoes. Further, the system 680 can easily determine asubpixel accuracy for each circle 710. In some embodiments, cornercircles (e.g., 710) may be present in each of the plurality of dominoes706. Having a corner circle 710 present in each of the dominoesfacilitates reading the locating markers 706, and may allow the system680 to read the locating markers at increased distances because there isa uniform size of features. Having uniformed sized features prevents asubset of the features from disappearing from the binzrized image beforeall the features disappear. For example, if all the features 710 are thesame size, then the system 680 may either detect all the features, ordetect none of the features if the locating marker 708 is outside adetection range.

In some embodiments, the locating markers 706 can include a fiduciarymarker 708. A fiduciary marker may refer to a marker that can bedetected by system 680 with minimal computation power. In someembodiments, the system 680 can detect the locating markers 700 directlyfrom input that is a black-and-white image (possibly as a binarizationof an image with more data, e.g. grayscale or full color).

In some embodiments, the system 680 can detect locating markers 706using a contour tree of a binarized image. The contour tree may refer toa tree of blobs. A blob may refer to a region of the same color. Thecontour may refer to or include a border of the blob or the region ofthe same color. The blob may have a shape, such as a circle, square,triangle, polygon, oval, ellipse, rectangle, pentagon, outline, oranother shape that allows the system 680 to detect a location marker.

In some embodiments, the blobs can be organized in a tree such that eachnode in the tree corresponds to a blob. Further, a node may be a childof another node if the child blob is encompassed by the parent blob. Forexample, in an image of the capital letter “B”, there are four blobs:the white background, the black of the letter, and two white blobs ofthe inner parts of the B. They are organized in a tree such that theletter is the child of the background and the two inner blobs are bothchildren of the letter.

In some embodiments, location markers may include dominoes asillustrated in FIG. 7B. While rectangle dominoes are illustrated in FIG.7B, other markers with patterns or other shaped blobs can be used. Forexample, rather than a rectangle marker 708, the marker may be apolygon, circle, ellipse, square, triangle, pentagon, etc. The blobs 710may be circles, or other shapes. The collection or plurality of markersmay be referred to as a scene 706 or plurality of markers 706 orplurality of candidate location markers 706. A marker 708 may be acandidate marker because the system 680 may perform initial processingto identify the image and determine whether the image is a locationmarker based on a threshold test or satisfying a criteria (e.g., whetherblobs are present in predetermined locations, is there a patternpresent, or other signature that indicates that the image corresponds toa location marker 708).

The location markers may include one or more rows 712 including one ormore markers 708; and one or more columns 714 including one or moremarkers 708. In some embodiments, the plurality of location markers 706or scene 706 may be symmetrical (e.g., a same number of rows andcolumns). In some embodiments, the plurality of location markers 706 orscene 706 may not be symmetrical (e.g., a different number of rows andcolumns).

Each of the dominoes 706 may include a recognizable signature in thecontour tree. For example, a domino may include 10 white blobs inside ablack blob. The white blobs may not have children blobs. The dominoconfiguration may include a contour tree with ten white children thatare leaves of the black background tree. Therefore, if the system 680detects this configuration (e.g., a black blob with 10 white blobs), thesystem 680 can take the black blob and process it as a fiducial marker.This additional processing may end up rejecting the domino as a marker,or accepting the domino as a location marker. This possibility extendsto any recognizable signature in the contour tree, which may involve avariable number of children blobs, as long as it is distinctive enoughthat just from the contours one can have a good probability that it is amarker and spend additional computational resources to study it closer.

Thus, the system 680 can be configured to perform an initial assessmentof a detected image using an initial image processing technique. Duringthe initial processing technique, the system 680 identifies a contourtree to determine if the contour tree matches or satisfies an initialscreening. For example, if the system 680 detects a black blob and 10white blobs (e.g., as shown in domino 708), the system 680 may determinethat the image may include a location marker, and forward the image forfurther processing. By performing an initial assessment, the system 680can prescreen images and select a subset of the images for further, morecomputationally intensive processing. Thus, the system 680 can increaseefficiencies and reduce the amount computational resources used todetermine the location of a tool relative to a working surface.

In some embodiments, the marker that can be detected extremely quicklyby binarizing an input image, computing the contour/blob tree, orlooking for a known signature. In some embodiments, the location markermay encode data into each fiducial (e.g., 708) and be easy to detect.For example, the fiducial marker 708 may encode a number, which allowsthe system 680 to keep track of (manage, maintain, identify, ordetermine) multiple fiducials present in a scene (e.g., a scene mayrefer to location markers 706). The number of the fiducial 708 may beunique in the scene 706, or may not be unique in the scene 706. In someembodiments, marker such as each of the dominoes 708 includes a patternof white blobs that encodes a number in binary.

In some embodiments, a marker 708 may include blobs (e.g., 710) that arepositioned in a predetermined location. A marker 708 may include blobsin each of the four corners, allowing the system 680 to determine notjust the presence of the fiducial marker 708 but a layout for it (suchas the position and orientation of a marker relative to the camera 682.Including blobs in predetermined positions may improve the ability ofsystem 680 to decode a message encoded in the marker itself. Forexample, if the blobs are arranged in a grid, recognizing the cornersprovides a layout of the grid and allows the system 680 to map each gridsquare to a 1 or 0 for a blob being present or absent. In someembodiments, the system 680 may use the blobs in the predeterminedlocation of the marker to detect the layout of the domino or marker 708,but then parse some encoded data in another way, which may or may not beencoded in the binarized image/contour tree.

In some embodiments, the marker 708 may include blobs that are shapesthat can then be resolved with subpixel accuracy by referring back tothe full-color (or grayscale) image. For example, the system 680 mayidentify the blobs as circles (or preconfigured to identify the blobs ascircles). The system 680 can determine the bounding box of each blob inthe binarized image. The system 680 can then use the correspondinggrayscale pixels in the grayscale image to fit an ellipse (circle viewedin perspective) to the pixels, giving a subpixel accuracy. The system680 may more accurately detect the position and orientation of thefiducial 708 relative to the camera by using this subpixel-accuratedetections of the blobs. This position and orientation can then be fedforward in the system 680 for further processing, such as localizationof the camera in 3D space.

Referring now to FIGS. 8A-8B, systems, methods, and apparatus fordirecting and extracting dust is shown. Dust extraction may refer to theevacuation of particles of material that have been removed from a bulkworkpiece (surface of a material, work surface) during a machiningprocess such as milling, routing, sanding, etc. In the domain ofwoodworking, the dust may be saw dust. Effectively extracting dustfacilitates maintaining a clean working environment, safe air forbreathing that is free of dust, and prevents a buildup of dust in thevicinity of the tool that can otherwise impede its cutting action andalso result in the generation of excessive heat. Additionally theaccumulation of wood dust can create an explosion risk. Further, forautomatically guided tools (such as system 680) that utilize an opticalmethod for localization (e.g., camera 682), dust can interfere with thetool's ability to determine a location of the tool relative to thesurface of the material. Systems, methods and apparatus of the presentdisclosure efficiently evacuating dust from the working area of a tool.In some embodiments, dust can be routed away from the working area in acontrolled direction in the absence of a vacuum source.

FIG. 8A illustrates a tool 800 configured to direct and evacuate dust inaccordance with an embodiment. The tool 800 includes a rotating cutter 1(or tool tip, or cutting member, or working member) that shears material2 as the rotating cutter 1 moves axially, laterally, or a combinationthereof through the material 2. The tool 800 includes a tool frame 3.The tool frame 3 may include a cavity formed of a void in the tool frame3. The cavity 3 may be further formed by a space 4 where portions ofworking material 2 have been removed or cut away. A cutting member orrouter bit or tip of the tool can extend through cavity 3. The cavity 3can form one or more channels or a portion of a channel. The channeldirects air flow 6. Channels are further illustrated in FIGS. 9A-9B. Thetool can include a camera 10, which can include one or morefunctionality of camera 682. The camera 10 can include or be referred toas a sensor, such as an image sensor, infrared sensor, or laser sensor.

In some embodiments, the rotational motive power for the rotating cutter1 may be generated by a router 5 or spindle 5 (e.g., a woodworking trimrouter, or metal cutting tool, or plastic cutting tool, etc.) thatincludes an integral fan 802. The fan 802 may be a separate fan that isintegrated into the spindle 5, or the fan 802 may refer to an airflowthat is generated as a by-product of the spindle 5 rotating the cuttingtool 1. In some embodiments, the fan 802 may be external to the tool,such as external to the spindle 5. The fan 802 can include one or morevanes or blades in an arrangement that, when rotated, generates airflow.This fan 802 can generate a downward airflow 6 that drives dust out ofthe collection cavity formed by the tool frame 3 and space 4 and alongchannels in the tool's base plate 7. These channels direct dust towardsthe front of the tool 8, which keeps dust from accumulating to the rearof the tool 9 where an optical locating system 10 (e.g., camera 682) maybe aimed. In some embodiments, the front 8 of the tool 800 may refer toa portion of the tool that faces away from the direction the tool iscutting or a portion of the tool closer to the user of the tool. In someembodiments, the rear 9 of the tool 800 may refer to a portion of thetool that faces the direction the tool is cutting or a portion of thetool further away from the user of the tool. In some embodiments, therear 9 of the tool refers to the portion of the tool 800 where a camera10 is aimed. The tool 800 can include a vacuum port 11 that opens intoone of the channels formed by voids 3 and 4 that receives air flow 6.

FIG. 8B illustrates an embodiment of a tool 801 similar to tool 800 thatincludes a vacuum source 12 attached to the vacuum port 11. The vacuumsource 12 biases airflow towards the vacuum source 13. This can extractthrough the connected channel formed by voids 3 and 4 in base plate 7and into the vacuum source 12. In this configuration, dust may beefficiently removed from the tool without entering the surroundingenvironment (e.g., rear of tool 9).

The channel formed by cavities 3 and 4 allow the airflow 6 generated bythe fan 802 of the tool spindle 5 and the airflow generated by thevacuum source 12 to act along a common path to remove dust. Thisprovides for efficient dust extraction system as the vacuum source 12 isnot fighting against the airflow generated by the integrated spindle fan802.

FIG. 9A illustrates a top-down perspective view of an apparatus 900 fordirecting and extracting dust. The apparatus 900 may be coupled to, bepart of, or be formed of one or more component of systems or apparatus800 or 801. In some embodiments, apparatus 900 includes the base plate 7of the tool 800. The baseplate 7 includes channels 904 a-b formed by thevoid or cavity 3 in the base plate 7. A portion of the base plate 7faces or rests on or is opposite the material 2. The fan 802 generatesair flow 6 that flows downward towards the material 2. The vacuum source12 generates airflow 13 towards the vacuum source 12 and vacuum port 11.The direction of airflow 6 as going towards the material 2 isillustrated by an X, while the airflow 13 shown going towards the vacuumport 11 is illustrated by a dot in a circle.

In some embodiments, the channels 904 a-b formed in base plate 7 areV-shaped. In some embodiments, there may be two channels 904 a and 904 bthat extend from the cavity 3. In some embodiments, there may be onechannel (e.g., just channel 904 a). In some embodiments, there may be aplurality of channels (e.g., two or more channels). One of the pluralityof channels may include a vacuum port 11 coupled to a vacuum source 12.The channels 904 a and 904 b may form a U shape. The channels 804 mayinclude a third channel that extends perpendicular to channels 904 a and904 b via the cavity 3.

The channels 904 a and 904 b may form an angle 906. The angle 806 mayrange from 1 degree to 180 degrees. In some embodiments, the angle 906may be 90 degrees, 45 degrees, 60 degrees, 120 degrees, etc. The angle906 may be selected such that dust from material 2 is effectivelydirected away from the rear 9 of the tool and towards the front 8 of thetool via channel 904 a-b and air flow 6 and 13.

The channels 904 a-b may include a channel depth. The channel depth maybe the same for channel 904 a and channel 904 b, or may be differentamong the different channels. The channel depth may be greater thanzero. The channel depth may be a value that ranges from 0.02 inches to 2inches. The depth may be less or greater based on the type of tool ortype of material being cut. For example, a size of particles beingdirected or extracted may determine a channel depth (e.g., shallowerchannel depth for smaller particles, and deeper channels for biggerparticles).

In some embodiments, a first component of the air flow 6 and 13generated from fan 802 may be greater than a second component of the airflow 6 and 13 generated from vacuum source 12. In some embodiments, afirst component of the air flow 6 and 13 generated from fan 802 may beless than or equal to a second component of the air flow 6 and 13generated from vacuum source 12.

In some embodiments, the air flow generated from vacuum source 12 may bedetermined such that the air flow holds the tool 800 (or apparatus 900)to the material 2. This may increase the friction between the portion ofthe tool touching the material, which may increase stability whilecutting or performing the task on the material 2.

FIG. 9B illustrates an apparatus 902 for directing or extracting dustaway from a rear 9 of a tool. FIG. 9B illustrates a top-down perspectiveview of the apparatus 902 or base plate 7 including channels 904 a-b.The apparatus 902 may be similar to or include one or more component ofapparatus 900. In some embodiments, the apparatus 902 includes a vacuumport 11, but is not coupled to a vacuum source (e.g., as shown inapparatus 900). While the apparatus 902 may not be coupled to a vacuumsource at vacuum port 11, the apparatus 902 may still direct and extractdust via channels 804 and air flow 6 generated by a fan (e.g., fan 802).

The vacuum port 11 may be positioned anywhere along channel 904 a orchannel 904 b. In some embodiments, the vacuum port 11 may be positionedcloser to an edge or corner of the base plate 900 relative to the cavity3. The distance 908 between the vacuum port 11 and edge of the baseplate 902 may be greater than zero. The distance 910 between the vacuumport 11 and the cavity 3 may be greater than zero. The distance 910 maybe different from distance 908. The distance 910 may be greater thandistance 908. The distance 910 may be a multiple of the distance of 908.The distances 908 and 910 may be determined such that dust can beeffectively and efficiently directed and extracted away from rear 9 oftool.

FIG. 9C illustrates a bottom perspective view of base plate 910. Baseplate 910 may correspond to base plate 7. Base plate 910 includeschannels 912 a-b, which may correspond to channels 904 a-b. The baseplate 910 includes a cavity 916 that may correspond to cavity 3. Thebase plate 910 includes a vacuum port 914 in channel 912, which maycorrespond to vacuum port 11. The vacuum port 914 may or may not beconnected to a vacuum source.

The base plate 910 can be made of any material that facilitatesoperation of the system 680 or tool 800. The material may be metal,plastic, an alloy, or other material that provides adequate structuralsupport for the tool 800 and friction to allow the tool to glide on thesurface while providing some stability.

FIG. 9D is a top down perspective view of base plate 920, which maycorrespond to an embodiment of the base plate 902 of FIB. 9B. The baseplate 920 includes a cavity 922 through which the cutting member or tipof the tool may extend. The base plate 920 may include a vacuum port924.

The base plate 920 may include channels on the bottom of the base plate920 (e.g., the portion or side of the base plate opposite the materialon which a task is to be performed). The base plate 920 may includeadditional openings or cavities or grooves for one or more screws, orcoupling mechanisms used to couple the base plate 920 to a tool, such astool 800.

Referring to FIG. 10A, a system, method and apparatus for determining aposition of a tool tip relative to a work surface or material is shown.The system, method and apparatus can calibrate position detection forthe tool. In some embodiments, system 680 can be configured, designed orconstructed to determine the position of the tool tip relative to thework surface. The system 1000 (or tool 1000) can move, position, orcontrol motion of a tool tip 24 in one or more directions (e.g., FIG.10B shows the tool tip 24 touching the surface of the material 2). Thecontrol may be manually or automatically motivated. In some embodiments,the tool 1000 may include or be configured with automatic control of theheight of a rotating cutter 24 relative to the surface of a workpiece ormaterial 2. The system 1000 can include one or more function orcomponent of the system or apparatus of FIGS. 1-9 and 11A-11B.

The system 1000 (or tool 1000) can calibrate position detection for thetool. The system 1000 can include a base 18 coupled to the tool 1000.The base 18 can be in contact with a working surface 2. In some cases,the base 18 can include a pad 22. For example, the base 18 can include apad 22 such that the base 18 is in contact with the working surface 2via the pad 22. Thus, and in some embodiments, the base 18 can refer tothe base 18 and the pad 22. In some embodiments, the base 18 may not bein contact with the working surface. The base 18 can be in contact withthe sensors 23 that are in contact with the pad 22, and the pad 22 canbe in contact with the working surface or workpiece or material 2.

The system 1000 can include one or more computing device having one ormore processors. In some cases, the system 1000 can include the one ormore computing devices remote from the tool. For example, the tool caninclude a wireless or wired communication interface that can transmitand receive data or control information from one or more computingdevices that are remote from the tool.

The system 1000 can include one or more sensors 23 communicativelycoupled to the computing device. The system 1000 can include a motor 19controlled by the computing device to extend and retract the tool tip 24towards and away from working surface 2. The motor 19 can control orinclude or refer to one or more components of the system 1000 configuredto extend or retract the tool tip 24, including, for example, a moveablecarriage 15.

The system 1000 can identify, via the one or more sensors 23, a firstvalue of a parameter indicative of an amount of force exerted by aportion of the base on the working surface. For example, the sensor 23can include a force sensor 23. The system 1000 can determine the firstvalue as a first force value that indicates a default or initial forceexerted by the base 23 on the material 2. This may indicate a weight ofthe tool. The force can be measured or determined in Newtons or pounds.The sensor 23 can repeatedly detect or measure the value of theparameter based on a time interval (e.g., every 0.1 second, 0.5 second,1 second, 2 seconds, 3 seconds, 5 seconds, or some other time interval).The sensor 23 can compare a first value or first measurement with asecond or subsequent measurement. The sensor 23 can repeatedly compare ameasurement with a subsequent measurement until the sensor detects achange or difference (e.g., by 0.5%, 1%, 2%, 3%, or an absolute changesuch as 1 N, 0.5 N, 0.25 N, 0.1N, 0.05N, or 2N) between measurements.The difference can refer to a difference by a predetermined threshold.The threshold can be fixed or dynamic. The threshold can be based on aresolution of the sensor 23.

The system 1000 can instruct the motor 19 to instruct the motor toextend the working member or tip 24 towards the working surface 2. Thesystem 1000 can then identify, via the sensor 23 upon the working member24 contacting the working surface 2, a second value of the parameter.This second value can be a second force value. The second force valuecan be less than the first force value determined by the sensor 23 whenthe tool tip 24 was not in contact with the working surface. In somecases, there may be multiple sensors 23 and each sensor can determine afirst force value and a second force value. In some cases, a firstsensor can determine a first force value that is different from a firstforce value detected by a second sensor. The first values can refer towhen the tool tip is not in contact with the material 2. The first andsecond sensors may identify different first values because due to thecenter of gravity of the tool not located evenly in between the firstand second sensors. Thus, when the tool tip 24 contacts the material 2,a second force value detected by the first sensor may be different froma second force value detected by the second sensor. For example, whenthe tool tip 24 contacts the material 2, the base 18 of the tool maytilt in an angle (e.g., 1 degree, 2 degree, 5 degree, or 10 degrees).The tilting of the base 18 may cause the first sensor 22 to measure asecond force value that is less than the first force value measured bythe first sensor 22, while the second sensor 22 can measure a secondforce value that is greater than the first force value measured by thesecond sensor.

The system 1000 (or computing device) can identify the first value ofthe parameter based on a portion of the base 18 of the tool in contactwith the working surface 2. The system 1000 can identify, via the sensor23, the second value of the parameter based on the portion of the baseof the tool not in contact (e.g., partially in contact or exerting lessforce on the surface than previously being exerted) with the workingsurface responsive to the motor 19 causing the working member 24 tocontact the working surface 2. For example, not in contact may refer toor include less force being exerted by the portion of the base 18. Insome cases, the system 1000 can instruct the motor 19 to contact theworking surface 2 to tilt at least a portion the base 18. Tilting thebase 18 can refer to distributing the force exerted by the base 18 suchthat a first portion of the base 18 exerts greater force on the material2 than a second portion of the base 18. Tilting the base 18 can refer tochanging the distribution of force exerted by the portions of the base18. The system 100 can determine the z-axis position of the workingmember 24 relative to the working surface 2 responsive to the workingmember 24 tilting the base 18 of the tool responsive to the workingmember 24 contacting the working surface 2.

The system 1000 can compare the first value of the parameter with thesecond value of the parameter to generate a difference between the firstvalue and the second value. The system 1000 can determine an absolutedifference (e.g., a difference of an amount of force), or simplydetermine that there is a difference in that the two values are notequal to each other. The system 1000 can determine that if the first andsecond values for a particular sensor 22 are not equal, then it is dueto the tool tip 24 contacting the material 24 and offset or distributingthe force exerted by the base 18 onto the material 2. The system 1000can determine the z-axis position responsive to the first force valuebeing greater than the second force value because less force may beexerted by the base 18 onto the material 2.

Responsive to detecting this difference, the system 1000 can determinethat the tool tip 24 has contacted the material, and use thisinformation to determine a z-axis position of the working memberrelative to the working surface. For example, the system 1000 candetermine that this is the baseline or default position for the tool tip24. The system 1000 can calibrate the position of the tool tip 24 suchthat this is a zero position. As the system 1000 retracts the tool tip24 away from the material, the system 1000 can monitor or track thedistance of the tool tip 24 from the calibrated zero positioncorresponding to the surface of the material 2. For example, the system1000 can control or instruct the motor 19 to retract or move the tooltip 24 a distance (e.g., 1 millimeter, 5 millimeters, 1 centimeters, 5centimeters, or 10 centimeters) away from the calibrated zero positionwhich may correspond to the surface of the material. The system 1000can, in some cases, instruct or control the motor 19 to insert the tooltip 24 a distance into the material 2. For example, the system 1000 caninstruct or control the motor 19 to insert the tool tip 24 onecentimeter beyond the calibrated zero position, which may insert thetool tip 24 one centimeter into the material 2. For example, the system1000 can make a one centimeter hole in the material using the calibratedzero position.

The system 1000 can instruct the motor 19 to retract the working member24 in contact with the working surface 2 away from the working surface2. The system 1000 (or sensor 23 thereof) can identify when the workingmember 24 is not in contact with the working surface by measuring athird value of the parameter. The third value of the parameter may begreater than the second value of the parameter because the tool tip 24is no longer offsetting the force exerted by the base 18 onto thematerial 2 (e.g., via sensor 23 or pad 22). The third value of theparameter may be equal to (e.g., substantially equal within 1%, 2%, 5%,or 10%) the first value of the parameter when the tool tip 24 was alsonot in contact with the material 2. The system 1000 can determine asecond z-axis position of the working member relative to the workingsurface responsive to a second difference between the first value andthe third value less than a threshold (e.g., the difference is less thana percentage of the first value or the third value such as 1%, 2%, 3%,5%, or 10%; or a force value such as 1 Newton, 0.5 Newton's, 0.01Newton's, 2 Newton's, 5 Newton's, or 10 Newton's).

Thus, to facilitate controlling the height of the rotating cutter 24,the tool may determine a reference or “zero” point so that the tool 1000(e.g., via cutting member 24) can be positioned to remove an amount ofmaterial 2. For example, the tool 1000 may plunge a rotating cutter 24 aspecified depth into a workpiece 2 before being moved laterally tocreate a groove. The tool may use a method to precisely determine theposition of the tool tip relative to the work surface. In someembodiments, the tool 1000 uses low cost sensors 23, such as forcesensors, that detect a delta or change in the force exerted by a portionof the tool 1000 on the material 2. In some cases, the sensors 23 caninclude capacitive sensors, photoelectric sensors, electromagneticsensors, load sensors, strain gauge load cells, piezoelectric crystals,hydraulic load cells, or pneumatic load cells.

As the tip 24 moves towards the material 2 and touches the material 2,the force exerted by the base 18 may be reduced because the force isbeing offloaded to the tip of the tool 24. Detecting this change inforce may indicate that the tip of the tool is touching the surface ofmaterial 2 and allow the tool to configure or set or initialize thisposition as a zero position. This may be useful for handheld power toolsincluding automatically guided tools, and may also be applied to fullyautomatic machine tools.

In some embodiments, the tool 1000 includes a router bit 1 mounted inthe spindle 14 of a router 5 (e.g., woodworking trim router). The router5 may be secured in a movable carriage 15 that slides on a guide rail16. The guide rail 16 may be mounted to a structural column 17. Thestructural column 17 may be fixed to a base 18 of the tool 1000. A motor19 may be fixed to the base 18 of the tool 1000 to rotate a leadscrew20. The leadscrew 20 may pass through a nut 21 on the movable carriage15. The leadscrew 20 may include square threads, acme threads, orbuttress threads. When the motor 19 rotates, the movable carriage 15translates in proportion to the pitch of the leadscrew 20.

In some embodiments, the movable carriage 15 may be mounted to a movingstage which is constrained in the Z direction by the frame. In someembodiments, the Z column or guide rail 16 may be mounted to a moving XYstage which is constrained in the Z direction by a frame of the device1000. For example, the tool or device 1000 can include a rig or framewith a stage that may be positioned on the surface of a piece ofmaterial such as wood. The tool can be electrically or mechanicallycoupled to the frame, and the frame together with the tool can be passedover the material. The tool can move (or provide instructions for a userto move) the frame, stage, or tool to a desired XY or Z coordinate onthe material. For example, the tool may include one or more components(e.g., rig, tool, stage, etc.) of the system described in U.S. PatentApplication Publication No. 2015/0094836. The U.S. Patent ApplicationPublication No. 2015/0094836 is hereby incorporated by reference hereinin its entirety.

In some embodiments, the tool 1000 may use one or more otherconfigurations or techniques to move the tip 24 of a tool 1000 relativeto the work surface. Other configurations may include a power screw,translation screw, ball screws, roller screws, fluid power, tear trains,worm drives, rack-and-pinion drives, electromagnetic actuation,piezoelectric actuation, hydraulic lifts, electrical lifts, rotary lift,pneumatic lift, mechanic lifts, levers, gears, etc.

The base 18 of the tool (or device) 1000 may be separated from the worksurface 2 by a pad 22 on which the device 1000 rests. In someembodiments, one or more force sensors 23 may be positioned between thepad 22 and the base 18 of the device 1000. The gravitational forcegenerated by the weight of the device 1000 partially or fully passesthrough the one or more force sensors 23 when the device 1000 is restingon the work surface 2.

To locate the tip 24 of the cutting tool 1000, the system or device 1000may move the carriage 15 closer to the work surface 2, which moves thetip 24 towards the work surface. As this motion is performed, the forcepassing through the force sensors 23 may be measured (e.g., measuredresponsive to a motion, measured periodically, measured based on a timeinterval such as every millisecond, 10 milliseconds, 1 second, etc.).Once the tip 24 of the cutting tool makes contact with the work surface2, additional motion results in a fraction of the weight of the device1000 to be transferred to the work surface 2 through the tool tip 24,and the force passing through the sensors 23 is correspondingly reduced.The system detects the change in force on the one or more sensors 23 andthe motion of the carriage may be stopped. The position of the carriage15 is recorded and may correspond to the point at which the tool tip ispositioned at the surface of the work. Because the tool tip and the worksurface may be stiff, a detectable transfer of weight occurs over verysmall distances and the error of this method may correspond to less than0.0005″ using a ¼″ carbide routing bit on a birch plywood surface.

The system 1000 can repeatedly extend and retract the tool tip 24towards and aware from the material 2 or a surface (e.g., desk, bench,floor, or other support structure) supporting the material 2. The system1000 can repeatedly extend and retract the tool tip 24 to generate orcreate a 3-dimensional map of the material 2.

In some cases, the system 1000 can extend the tool tip 24 adjacent to anedge of the material 2. The system 1000 can extend the tool tip 24adjacent to the edge of the material 2 until the tool tip 24 contacts asurface supporting the material 2. The system 1000 can determine athickness of the material by determining the distance beyond the surfaceof material 2 the tool tip 24 extends in order to contact the surfacesupporting the material 2. The system can determining these positionsusing the force sensors 23 to detect when the tool tip 24 contacts thematerial 2 or the surface supporting the material. For example, thesystem 1000 (or motor 19) can extend the working member 24 towards asurface supporting the working surface. A part of the base 18 of thetool can be in contact with the working surface 2, while a part of thebase 18 of the tool may be off the material 2. Or, in some cases, thebase 18 may be in contact with the material 2, and the material can beshaped or configured such that the tool tip 24 when extended may contactthe surface supporting the material 2 as opposed to the surface; or thetool tip 24 may extend through a hole in the material 2 to contact thesurface supporting the material 2. The system 1000 (e.g., via sensor 23)can detect the working member 24 contacting the surface supporting theworking surface. For example, the system 1000 can detect a third valueof the parameter (e.g., force), and determine a thickness of the workingsurface 2 responsive to a second difference between the first value andthe third value greater than a threshold (e.g., the difference can begreater than 1%, 2%, 5%, 10%, of one of the first value or third value;or the difference can be greater than a force value such as 1 Newton,0.5 Newton's, 0.01 Newton's, 2 Newton's, 5 Newton's, or 10 Newton's).

The system 1000 can determine multiple location points based on theworking member 24 of the tool contacting the working surface. Forexample, the system 1000 can repeatedly extend and retract the workingmember of the 24 to contact the material 2 and move the working member24 away from the surface. The system 1000 can record information eachtime the tool tip 24 contacts the material 2 (or does not contact thematerial 2). For example, the system 100 can record or identify locationpoints. Each location point can have an x-axis coordinate, a y-axiscoordinate, and a z-axis coordinate. The x-y coordinates can bedetermined using markers on the surface of the material and may berelative to a surface of the material or position on the surface of thematerial. The x-y coordinates can be determined using fiducial markerson the surface of the material, imaging techniques, or visualtechniques. For example, a second sensor of the tool (e.g., a visualsensor or camera) can determine the x-axis coordinate and the y-axiscoordinate of each of the location points using a fiducial marker placedon the working surface. The system can determine the z-coordinate (ordepth) by extending the tool tip 24 until the tip 24 contacts thesurface, and measuring the depth relative to a calibrated zero position.The calibrated zero position can be a position on the surface of thematerial. The system 1000 can generate a three dimensional map of theworking surface 2 using the location points.

The system 1000 can measure the geometry of the work surface 2 bycorrelating the tool tip 24 position with device (e.g., tool 1000)position on the plane of the work surface 2. To do so, the tool tip 24(e.g., a cylindrical tool with a conical or spherical tip) can first berelated to the reference frame of the tool 100 by detecting the positionof the tool tip 24. Once the position of the tool tip 24 is knownrelative to the tool's reference frame, the tool can be positionedlaterally over a surface of interest (e.g., working surface 2) todetermine the vertical position of the working surface. The verticalposition of the working surface can refer to a surface of the materialof the working surface. In some cases, the vertical position canindicate a recess, cavity, indent, or concave portion in a piece of woodwhose depth is of interest. In some cases, the vertical position canindicate a raised portion, bump, protrusion, or convex portion in apiece of wood whose depth is of interest. The tool tip can then beinserted, extended, lowered, plunged otherwise moved until the tool tipcontacts the surface of the portion of the material (e.g., recess orprotrusion). The additional displacement of the tool tip beyond the topportion of the surface where the tool tip first contacted the worksurface can indicate the depth of the recess. Similarly, the reductionin displacement of the tool tip above the portion of the surface wherethe tool tip first contacted the work surface can indicate a height ofthe protrusion. If the surface profile of the recess was of interest,the tool might be moved around the recess to multiple points. The toolcan determine, at each of the multiple points, the depth. The tool canrecord both the depth and lateral position of the tool (e.g., x, y, andz coordinates, where x and y coordinates can refer to the lateralposition and the z coordinate can refer to the depth). The lateralmotion could be accomplished automatically using a built-in positioningstage, or performed manually by the user, or a combination of both.

The system 1000 can identify or determine a center position of a hole ona work surface 2. For example, a tool 1 with a conical tip 24 can befitted into the system. The tool 1 can then be positioned approximately(e.g., within 5%, 10%, 15%, 20%, 25%, 30%, 50%, 75%, or 90% of thediameter of the hole) over the center of the hole, and plunged until thetip 24 contacts the circle of the hole. Because the tool tip 24 can beconical, the tool tip 24 can cause the tool to center over the hole. Thetool can then determine the lateral position (e.g., x and y coordinates)using, for example, a vision system with a camera 10 to ascertain theposition of the hole.

The system 1000 can include or communicate with a computing device,processor or microprocessor (such as a processor of system 680). Thecomputing device can include the one or more process of system 680. Thesystem 1000 can use the computing device to control the motion of thepositioning motor and also to measure the force passing through the oneor more force sensors 23. Sensors 23 may include, e.g., force-sensitiveresistors, piezoelectric sensors, strain gages, load pins, shear beams,tension links, magnetic level gauge, torque sensor, load cells,hydraulic load cells, pneumatic load cells, elastic devices,magneto-elastic devices, plastic deformation, foil strain gauges, etc.

In some embodiments, the tool can detect the tilt using a camera, visualinformation, gyroscope, or 3-axis accelerometer. The tool can include acamera 10 (also illustrated in FIG. 8A), or other sensor. Camera 10 caninclude one or more component or functionality of camera 682. The camera10 can determine a shift in a captured image corresponding to a tiltresulting from the base lifting. The camera 10 can take a first pictureor image before the tool brings the tool tip 24 into contact with theworking surface 2, and then take a second image when the tool tipcontacts the working surface. The camera 10 can repeatedly take imagesbased on a time interval (e.g., every 1 second, 2 seconds, 3 seconds,0.5 seconds, or 5 seconds) and compare a first image with a subsequentimage to identify a tilt. The camera 10 can take a burst of images andthen compare the images with one another to detect when the tool tipcontacted the surface to cause the tilt. In some cases, each image inthe burst of images can be associated with a time stamp. Each of theimages can further be associated with, tagged with, or otherwisecorrespond to a position of the tool tip. The system can determine whichimage of the burst of images first indicates a tilt (e.g., an object inthe image taken by camera 10 may appear closer when the tool 1000 istilted towards the rear of the tool when the tool tip comes into contactwith the material 2). In some cases, the system 1000 can determine adifference or misalignment in pixels between a first image and asubsequent image. Responsive to detecting the misalignment in thepixels, the system 1000 can determine that the tool tip contacted thematerial 2 at the timestamp corresponding to the subsequent or secondimage having the misaligned pixels relative to a first image or previousimage. The camera can compare the first image with the second image toidentify a tilt or variation between the two images.

The sensor 10 can include an image sensor or camera. The parameter caninclude a pixel. The pixel can have a location in the image. The system1000 can capture (e.g., via the image sensor) a first image comprising apixel with a first value (e.g., binary value, 256-bit value, red, greenblue value, grayscale value, brightness value, or numerical value). Thesystem 1000 can capture a second image comprising a second value of thepixel. The second value can be for the same pixel as the first value.The pixel can be a location in the image. The system 1000 can comparingthe first image comprising the first value with the second imagecomprising the second value to identify the difference between the firstvalue and the second value. The system can compare one or more pixels inthe first image with one or more pixels in the second image to detect adifference. The system can compare the two captured images to determinethat they are misaligned. The images may be misaligned due to the basebeing tilted in an angle, which may cause the camera to capture thesecond image at a different angle or from a different perspective ascompared to the first image. Thus, the system can attribute themisalignment to the tool tip 24 contacting the surface of the workingmaterial and tilting the base.

The tool can determine the proximity of the tool tip 24 to the workingsurface 2 using a capacitive sensor 10 or an electromagnetic sensor 10.For example, the electromagnetic sensor 10 can sense or detect a changein inductance of a sensing coil in proximity to the tool tip 24 orworking member 24 that includes metal by sensing eddy currents inducedin the metal.

In some cases, the tool 1000 can include an accelerometer. For example,sensor 23 or sensor 10 can include an accelerometer, such as a 3-axisaccelerometer or gyroscope. The accelerometer can indicate the tiltresponsive to a motion or sudden motion caused by the base lifting. Forexample, the accelerometer can determine a first value indicating theacceleration of the base of the tool when the tool tip is not in contactwith the surface. The first value can be zero, for example, because thebase may be resting on the working surface. The accelerometer candetermine the second value when the tool tip touches or contacts thesurface. The second value or second acceleration value can indicate anacceleration of the base, an impact, a movement, a force or otherdisplacement of the base caused by the tool tip contacting the workingsurface and moving the base that is mechanically connected to the tooltip. The computing device can compare the first value with the secondvalue to identify the acceleration of the base of the tool based on theworking member contacting the working surface. In some cases, thecomputing device can determine that the first value and the second valueare not equal or substantially equal (e.g., within 1%, 2%, or 5%), anddetermine the tool tip contacted the working surface based on therebeing a difference in acceleration.

The tool can determine or detect additional information about the toolincluding tip or working member position, diameter, or tool geometry.Determining the geometry of the tool can include or refer to determiningthe diameter of the cutting tool. The tool geometry information can beused to automatically determine a length of a cutting flute of theworking member and an angle of the cutter (e.g. a V carving bit or helixangle). For example, the tool can include cameras 10 or a break-beamsensor 10 (e.g. laser break beam sensor, infrared break beam sensor,photoelectric sensor, or optical sensor) proximate to the tool tip 24.The working member 24 can be dropped into the line of action of thesensors 10 and the tool can detect the position of the working member 24when the working member 24 breaks the beam formed by sensors 10. In somecases, the axis of the beam can be pre-calibrated relative to thecoordinate frame of the tool.

In some cases, the system can include one or more vision cameras 10aimed at the tool tip 24 or tool member 1 to determine the position ofthe working member 1 or tool tip 24. The vision camera 10 can bepre-calibrated to the tool coordinate frame to detect the tool tip 24.In some cases, the vision camera can include a linear charge coupleddevice (CCD) sensor or other image sensor. A linear CCD sensor may useless processing than a vision camera to detect the tool tip.

The system 1000 can measure the diameter of the working member 1 or tooltip 24. The tool can shift the tool tip 24 around while measuring ordetermining the position of the tool tip. By shifting the tool tip, thetool can use a single break-beam sensor 10 to detect tool diameter bypassing the tool left-to-right through the sensor 10. The lateral motionof the tool can cause a first break and then un-obstruct the beam toprovide a measure of the tool diameter. Since router bits can havehelical flutes, the tool can perform multiple measurements along thelength of the tool to determine the diameter. The tool can determine thediameter using eddy currents or capacitive sensing with aone-dimensional sensor to gather multi-dimensional information about thetool geometry by correlating the sensor data to the tool position. Thetool can determine additional information about the tool tip 24 such astip angle in the case of a v-cutting bit. Furthermore, the tool caninclude a vision camera 10 to detect geometric properties of the tool.

The system 1000 can include or be configured with a hybrid positioningsystem to position the working member of the tool. For example, thesystem can include a stage. The system can include a skid pad proximateto the stage to facilitate moving the stage. The system can include atleast one motor adapted to move the stage. The system can included atleast one motor controller that controls the at least one motor. Thesystem can include a computing device or a processor in combination withone or more software applications for processing data and providinginformation to the at least one motor controller. The system can includea first sensor configured to capture first information of a surface of amaterial to build a map of the surface. The first information caninclude an image of the surface. The system can include a second sensorcommunicatively coupled with the processor. The second sensor cancapture second information of the surface used to determine at least oneof a location of the working member and an orientation of the workingmember relative to the surface. The computing device or processor canbuild the map of the surface using the first information captured by thefirst sensor. The computing device or processor can receive a designcorresponding to the map of the surface built using the firstinformation. The processor can display the design overlaid on the mapvia a display screen. The system can receive, via the second sensor, thesecond information of the surface. The system can determine, based onthe second information of the surface and based on the map, at least oneof the location of the working member and the orientation of the workingmember relative to the surface. The system can display the location ofthe working member overlaid on the map via the display screen. Thesystem can determine, based on the design registered on the map and atleast one of the location and the orientation, a desired location forthe working member. The system can provide motor control information tocontrol the at least one motor to move the stage and the working memberto the desired location while the tool is advanced in a first directionthat is within a selected range substantially adjacent to an outline ofthe design. The system can automatically realign the tool to a boundaryedge of the design in a second direction as the tool is advanced in thefirst direction.

For example, the system 1000 can use the determined z-axis position ofthe working member to provide, based at least in part on the z-axisposition of the working member, motor control information to control theone or more motors to move the working member from a first location to asecond location. The motor control information can include one or moreof x-axis information, y-axis information, or z-axis information. Thetool can be advanced in a direction that is within a range adjacent to apredetermined path for the working member of the tool.

In some cases, the system 1000 can receive first information from thefirst sensor and determine, based on first information of the surface ofthe material, at least one of a first location (e.g., x-y coordinates,or x-y-z coordinates) of the working member of the tool and anorientation of the working member relative to the surface using a map ofthe surface. The system can indicate, via a display screen of the tool,the first location of the working member of the tool relative to the mapof the surface. The system can retrieve a design corresponding to themap of the surface to identify a path for the working member of thetool. The system can compare the first location of the working member ofthe tool with the design to determine a second location for the workingmember of the tool corresponding to the path for the working member ofthe tool. The system can provide, based on at least one of the secondlocation and the orientation, motor control information to control theat least one motor to move the stage and the working member to thesecond location. The tool can be advanced in a direction that is withina range adjacent to the path for the working member of the tool.

The system can perform a constant speed technique to provide the motorcontrol information to control the at least one motor to move the stageand the working member to a plurality of subsequent locations while thetool is advanced in a corresponding plurality of subsequent directions.The system can automatically realign the tool to a boundary edge of thedesign in a third direction as the tool is advanced in a fourthdirection. The system can display a target range window rendering anillustration of a point of reference of the tool, an intended cut path,and a desired tool movement path. The intended cut path can indicate aposition in an x-y coordinates frame as well as z-axis depth.

The sensor can receive or capture a live feed of image data. The systemcan receive the live feed of image data captured by the sensor, and usethe live feed image data to compare a previous position (e.g., x-ycoordinates, or x-y-z coordinates) on the design and a preferred nextposition (e.g., x-y coordinates, or x-y-z coordinates) on the design toautomatically realign a position of the tool.

While FIGS. 10A-10B illustrate determining the position of a rotatingcutting tool 24 relative to the work surface 2, the method can apply toplotting pens, vinyl cutting knives, pipette tips, vacuum nozzles forpick and place machines, or any other system to determine a zeroposition of a working member 24 relative to a working material 2.

FIG. 10C illustrates a force sensor 23 adjacent to a pad in accordancewith an embodiment. The force sensor 23 may be temporarily placed thereto perform a calibration procedure to determine the zero position. Theforce sensor 23 may be removed after completion of the calibrationprocedure.

FIG. 10D illustrates a force sensor 23 positioned or placed on the topof the base plate 920. The one or more force sensors 23 can bepositioned anywhere on the tool 1000 such that the force sensor 23 candetect a change in force corresponding to the tool tip 24 touching thesurface of the material 2. The change in force may be a reduction indetected force because some of the force is being transferred via thetool tip 24 to the material rather than through the force sensor 23 ontothe material.

FIGS. 11A and 11B illustrate a tool 1100 with a base plate 1105. Thetool 1100 may include one or more component of the tool 1000, and baseplate 1105 may correspond to base plate 910. FIG. 11A illustrates thedust or particles that stay on the material when the dust extraction anddirection techniques are not being used, while FIG. 11B illustrates howthe dust direction and extraction techniques described herein can removethe dust from the material (e.g., via airflow generated by a fan and/orvacuum source traveling through a channel away from the rear of the toolor extracted via a vacuum port). The tool 1100 can moving, via a cavityor channel of a base plate of the tool, particles of material removedfrom the working surface by the working member. The tool 1100 canevacuate, by a vacuum, the particles via the cavity away from theworking member.

FIG. 12 illustrates a block diagram of a method of calibrating positiondetection of a tool, in accordance with an embodiment. In briefoverview, the method 1200 includes a tool detecting a first value of aparameter at 1205. At step 1210, the tool extends a working membertowards a working surface. At 1210, the tool detects a second value ofthe parameter. At 1220, the tool determines a position of the workingmember relative to the working surface. The method 1200 can be performedby one or more component or module of one or more system depicted inFIGS. 1-11B.

Still referring to FIG. 12, and in further detail, the tool detects afirst value of a parameter at 1205. The tool (e.g., via a sensor) candetect the first value of the parameter. The sensor can becommunicatively coupled to a computing device comprising one or moreprocessors. The parameter, or first value thereof, can indicate anamount of force exerted by a portion of a base of the tool on theworking surface or towards the working surface. The tool can detect thefirst value of the parameter with the portion of the base of the tool incontact with the working surface. For example, the portion of the basecan be resting or placed on the working surface or material. In somecases, the base can include a pad that is in contact with the workingsurface.

At step 1210, the tool extends a working member towards a workingsurface. The tool (e.g., via a motor controlled by the computing device)can extend the working member towards the working surface. When theworking member contacts the working surface, the base can be at leastpartially in contact with the working surface. For example, the workingmember can contact the working surface and at least partially lift ortilt a portion of the base. The portion of the base may or may not be incontact with the surface depending on how much the tool tip in contactwith the surface of the material lifts or tilts the base. In some cases,the base may still be in contact with the surface, but the amount offorce exerted by the base on the working surface may be less. Thislesser amount of force may correspond to the second value of theparameter.

At 1210, the tool detects a second value of the parameter. The tool(e.g., via the sensor) can detect when the working member contacts theworking surface by identifying a second value of the parameter that isless than the first value of the parameter. The second value can be lessthan first value because the force exerted by the portion of the basecan be less due to the tool tip distributing the force exerted by thebase. The force can be distributed such that the tool tip exerts some ofthe force onto the material, or such that another portion of the baseexerts greater force than a first portion of the base. For example, thetool tip can tilt the base such that a first portion of the base exertsless force than a second portion of the base. For example, the tool candetect the second value of the parameter with the portion of the base ofthe tool not in contact with the working surface responsive to the motorcausing the working member to contact the working surface. The tool candetermine the z-axis position of the working member relative to theworking surface responsive to the working member tilting the baseresponsive to the working member contacting the working surface.

At 1220, the tool determines a position of the working member relativeto the working surface. The tool (e.g., via the computing device) candetermine a z-axis position or depth of the working member relative tothe working surface responsive to a difference between the first valueand the second value greater than a threshold. The tool can calibratethe position detection system of the tool based on these detected z-axisposition. For example, the tool can set this position as a zero, initialor default position. The system can then determine the z-axis coordinateor position of the tool tip relative to the calibrated zero position. Insome cases, the tool may not calibrate the detected surface as a zeroposition, but may record the absolute distance of the spindle. As thetool tip length can vary based on the type of working member or tool,the position of the tip of the spindle can be predetermined by the toolas it may not be interchangeable.

The form and structure of embodiments of the present disclosure for usewith a cutting tool are provided and depicted in FIGS. 13-21. Theembodiments depicted in FIGS. 13-21 provide a system or rig 100 which isconfigured for use with a router 500. The system 100 includes twosupport legs 104 which are attached to a base housing 130 on the lowerend and terminate into a device mount 122 at the upper end. The devicemount 122 includes left and right display clips 124 to clamp or lock themonitor or smart device 570 into the device mount 122. The device 570includes a display screen 572 for the user to view the cutting path forthat particular use. The base 130 also has left and right handles orgrips 106 attached through handle support arms 108.

The lower end of the base 130 has a bottom plate 139 which encloses thestage 150 and a lower stage skid pad 151. The base 130 and bottom plate139 are fastened to one another such as by machined screws. As seen inFIG. 20, the bottom plate 139 has a bottom skid pad 141 attached to thebottom. The bottom skid pad 141 is used to assist movement of the rig100 along the surface of the material being worked on. The bottom skidpad 141 may be made of a high density polyethylene, Teflon, or othersuitable material which is both durable and suited for sliding along thematerial.

The router 500 is added to the rig 100 by attaching the router baseplate 510 to the stage 150. As seen in FIG. 21, the stage 150 hasseveral tool attachment points 164 for attaching the router base 510 tothe stage 150. The router base 510 has several router base support legs508 which forms a cage around the router bit 512. The router 500 alsohas a power cord 506 and an on-off switch 504. The rig 100 may beimplemented as a self-contained portable unit including an on-boardsource of power, such as a battery source.

The smart unit or monitor 570 can have an input cable 574 with a cableterminal or receptacle 576. If the device is a smart unit the CPU,software, and memory will be on the device itself. If the device 570 issimply a monitor then the cable 574 and receptacle 576 will connect tothe CPU unit.

As shown in FIGS. 14-19, the system 100 can contain a stage motor 210and a pivot motor 220. The stage motor 210 is used to control movementof the stage 150. The pivot motor 220 is used to control movement of thepivot arm 156 which pulls or pushes the stage 150 to convert therotational motion of the motors 210, 220 into a relatively linearmotion. The stage motor 210 and pivot motor 220 each have their ownmotor cap 212, 222 respectively.

The motors 210, 220 can be controlled by the stage motor driver 253 andthe pivot motor driver 254 which are connected to the printed circuitboard 250 and the microcontroller board 252. The microcontroller 252processes low level instructions from the smart device or CPU unit (i.e.a laptop). The instructions would be instructions to move the motors210, 220 to set positions (i.e. positions 150, 125) into the correctstep commands to drive the motors to those positions. The motors'orientations are tracked by homing them to a zero position once and thentracking all subsequent steps taken. Alternatively, the system could userotary encoders to keep track of the state of the motor shafts'orientations. The motors 210, 220 and the motor drivers 253, 254 arepowered by connecting the power plug receptacle 255 into a power source.

As shown FIGS. 15-16, the back of the rig 100 includes a camera support190. The camera support 190 may be one or more support members which areconnected to the upper stage housing 130 and terminate at the top of therig 100 where a camera 300 is mounted. The camera 300 and a lens 304 areplaced in a relatively downward position to capture images of thematerial being worked and the surrounding areas thereof.

The eccentrics can be used to convert the rotational motion of themotors into linear motion. Eccentrics are circular disks rotating aroundan off-center shaft. As the shafts are rotated, they produce linearmotion in the collars wrapped around the eccentric disks. Eccentrics areable to maintain the same low backlash accuracy of a precision linearstage while being less expensive. A linear displacement range of ½″ iswell within the capabilities of an eccentric. The tool can include twoeccentrics mounted to the frame and connected to a stage that can slideon its base. The eccentrics can be rotated by stepper motors, and byrotating them the stage can be moved within the frame. The size andshape of the various eccentrics can be varied to provide larger orsmaller relative movement of the tool 699 relative to the workspace.

To constrain the stage, one eccentric can be connected directly to thestage by a ball bearing coupling, while the other is connected by acoupling and a hinge. This linkage design results in a nonlinearrelationship between eccentric orientation and stage position. Near thecenter of the range moderate rotation of an eccentric produces moderatemotion of the stage. In contrast, near the edge of the range much largerrotations are necessary to move the stage a fixed amount. In the presentinvention, stage displacement is limited to approximately 95% of themaximum range to avoid positions with extreme nonlinearity. This linkagedesign also permits back driving, in that forces acting on the tool cancause the cams to rotate away from their target positions. However, thepresent invention makes use of adequately powered motors which havesufficient power to preclude back driving even in the presence ofsignificant forces.

As shown in FIG. 21, the upper stage housing 130 can be a one piece unitwith spacers 131, 133, 135 machined or formed into the upper stagehousing 130. The spacers 131, 133, 135 provide the required space forthe stage 150 and pivot arm 156 to move. The front spacers 131, sidespacers 133, and rear spacers 135 need not be formed as one unit.Instead, the front spacers 131, side spacers 133, and rear spacers 135could be separate pieces attached to the upper stage housing 130. Theupper stage housing 130 also accommodates several upper stage skid pads137. The upper stage skid pads 137 allow the stage stabilizing arms 152to move along the pads 137 with minimal friction.

The stage 150 is ideally made of a light but durable and strong materialsuch as aluminum or some other alloy. The stage 150 is most likelymachined to include one or more stabilizing arms 152, the stageeccentric arm member 154, tool attachment points 168, and an opening 160where the tool extends through the stage 150. In addition, a pivot arm156 is most likely machined from the same alloy or material as the stage150.

In operation the stage motor 210 moves in response to rotation of thestage motor shaft 184. There is a stage eccentric cam member 174attached to the stage motor shaft 184. When the stage motor shaft 184rotates the stage eccentric cam 174 rotates and the cam design causesthe stage arm member 154 connected to and surrounding the cam 174 tomove the stage 150. A bearing ring may be used between the cam 174 andthe stage arm member 154.

Additionally, when the pivot motor 220 moves the pivot motor shaft 186rotates. There is a pivot eccentric cam member 176 attached to the pivotmotor shaft 186. When the pivot motor shaft 186 rotates the pivoteccentric cam 176 rotates and the cam design causes the pivot arm member154 connected to and surrounding the cam 176 to move the pivot arm 156back and forth which causes the stage 150 to move relative to the pivotarm 156. A bearing ring may be used between the cam 176 and the pivotarm 156.

As the stage 150 and pivot arm 154 move, the stage stabilizing arms 152move along the upper stage skid pads and the lower stage skid pad 151(e.g., as in FIG. 13) to stabilize the stage 150 during movement.Further, the stage eccentric 174 and pivot eccentric 176 can include aboss. The boss gives the eccentric 174, 176 some extra material to housethe set screw which clamps on the stage motor shaft 184 or pivot motorshaft 186, thus securely attaching it to the respective eccentric 174,176. The pivot eccentric boss 187 is seen in FIG. 21. The stageeccentric boss is not shown in the figures as it is flipped relative tothe pivot boss 187 because the stage 150 and the pivot arm 156 areoperating on different planes.

Although various acts are described herein according to the exemplarymethod of this disclosure, it is to be understood that some of the actsdescribed herein may be omitted, and others may be added withoutdeparting from the scope of this disclosure.

It will be recognized by those skilled in the art that changes ormodifications may be made to the above described embodiments withoutdeparting from the broad concepts of the disclosure. It is understoodtherefore that the disclosure is not limited to the particularembodiments which are described, but is intended to cover allmodifications and changes within the scope and spirit of the disclosure.

The systems described herein may provide multiple ones of any or each ofthose components and these components may be provided on either astandalone machine or, in some embodiments, on multiple machines in adistributed system. The systems and methods described herein may beimplemented as a method, apparatus or article of manufacture usingprogramming or engineering techniques to produce software, firmware,hardware, or any combination thereof. In addition, the systems andmethods described herein may be provided as one or morecomputer-readable programs embodied on or in one or more articles ofmanufacture. The term “article of manufacture” as used herein isintended to encompass code or logic accessible from and embedded in oneor more computer-readable devices, firmware, programmable logic, memorydevices (e.g., EEPROMs. ROMs, PROMs, RAMs, SRAMs), hardware (e.g.,integrated circuit chip, Field Programmable Gate Array (FPGA),Application Specific Integrated Circuit (ASIC)), electronic devices, acomputer readable non-volatile storage unit (e.g., CD-ROM, floppy disk,hard disk drive). The article of manufacture may be accessible from afile server providing access to the computer-readable programs via anetwork transmission line, wireless transmission media, signalspropagating through space, radio waves, or infrared signals. The articleof manufacture may be a flash memory card or a magnetic tape. Thearticle of manufacture includes hardware logic as well as software orprogrammable code embedded in a computer readable medium that isexecuted by a processor. In general, the computer-readable programs maybe implemented in any programming language, such as LISP, PERL, C, C++,C#, PROLOG, or in any byte code language such as JAVA. The softwareprograms may be stored on or in one or more articles of manufacture asobject code.

Having described certain embodiments of methods and systems forvirtualizing audio hardware for one or more virtual machines, it willnow become apparent to one of skill in the art that other embodimentsincorporating the concepts of the disclosure may be used.

While various embodiments have been described and illustrated herein,those of ordinary skill in the art will readily envision a variety ofother means or structures for performing the function or obtaining theresults or one or more of the advantages described herein, and each ofsuch variations or modifications is deemed to be within the scope of theembodiments described herein. More generally, those skilled in the artwill readily appreciate that all parameters, dimensions, materials, andconfigurations described herein are meant to be exemplary and that theactual parameters, dimensions, materials, or configurations will dependupon the specific application or applications for which the teachingsare used. Those skilled in the art will recognize, or be able toascertain using no more than routine experimentation, equivalents to thespecific embodiments described herein. It is, therefore, to beunderstood that the foregoing embodiments are presented by way ofexample only and that, within the scope of the appended claims andequivalents thereto, embodiments may be practiced otherwise than asspecifically described and claimed. Embodiments of the presentdisclosure are directed to each individual feature, system, article,material, kit, or method described herein. In addition, any combinationof two or more such features, systems, articles, materials, kits, ormethods, if such features, systems, articles, materials, kits, ormethods are not mutually inconsistent, is included within the scope ofthe present disclosure.

The above-described embodiments can be implemented in any of numerousways. For example, the embodiments may be implemented using hardware,software or a combination thereof. When implemented in software, thesoftware code can be executed on any suitable processor or collection ofprocessors, whether provided in a single computer or distributed amongmultiple computers.

Also, a computer may have one or more input and output devices. Thesedevices can be used, among other things, to present a user interface.Examples of output devices that can be used to provide a user interfaceinclude printers or display screens for visual presentation of outputand speakers or other sound generating devices for audible presentationof output. Examples of input devices that can be used for a userinterface include keyboards, and pointing devices, such as mice, touchpads, and digitizing tablets. As another example, a computer may receiveinput information through speech recognition or in other audible format.

Such computers may be interconnected by one or more networks in anysuitable form, including a local area network or a wide area network,such as an enterprise network, and intelligent network (IN) or theInternet. Such networks may be based on any suitable technology and mayoperate according to any suitable protocol and may include wirelessnetworks, wired networks or fiber optic networks.

A computer employed to implement at least a portion of the functionalitydescribed herein may comprise a memory, one or more processing units(also referred to herein simply as “processors”), one or morecommunication interfaces, one or more display units, and one or moreuser input devices. The memory may comprise any computer-readable media,and may store computer instructions (also referred to herein as“processor-executable instructions”) for implementing the variousfunctionalities described herein. The processing unit(s) may be used toexecute the instructions. The communication interface(s) may be coupledto a wired or wireless network, bus, or other communication means andmay therefore allow the computer to transmit communications to orreceive communications from other devices. The display unit(s) may beprovided, for example, to allow a user to view various information inconnection with execution of the instructions. The user input device(s)may be provided, for example, to allow the user to make manualadjustments, make selections, enter data or various other information,or interact in any of a variety of manners with the processor duringexecution of the instructions.

The various methods or processes outlined herein may be coded assoftware that is executable on one or more processors that employ anyone of a variety of operating systems or platforms. Additionally, suchsoftware may be written using any of a number of suitable programminglanguages or programming or scripting tools, and also may be compiled asexecutable machine language code or intermediate code that is executedon a framework or virtual machine.

The concept described herein may be embodied as a computer readablestorage medium (or multiple computer readable storage media) (e.g., acomputer memory, one or more floppy discs, compact discs, optical discs,magnetic tapes, flash memories, circuit configurations in FieldProgrammable Gate Arrays or other semiconductor devices, or othernon-transitory medium or tangible computer storage medium) encoded withone or more programs that, when executed on one or more computers orother processors, perform methods that implement the various embodimentsdescribed herein. The computer readable medium or media can betransportable, such that the program or programs stored thereon can beloaded onto one or more different computers or other processors toimplement various aspects and embodiments described herein.

The terms “program” or “software” are used herein in a generic sense torefer to any type of computer code or set of computer-executableinstructions that can be employed to program a computer or otherprocessor to implement various aspects of embodiments as discussedabove. Additionally, according to one aspect, one or more computerprograms that when executed perform methods or operations describedherein need not reside on a single computer or processor, but may bedistributed in a modular fashion amongst a number of different computersor processors to implement various aspects or embodiments describedherein.

Computer-executable instructions may be in many forms, such as programmodules, executed by one or more computers or other devices. Generally,program modules include routines, programs, objects, components, or datastructures that perform particular tasks or implement particularabstract data types. Typically the functionality of the program modulesmay be combined or distributed as desired in various embodiments.

The data structures may be stored in computer-readable media in anysuitable form. For simplicity of illustration, data structures may beshown to have fields that are related through location in the datastructure. Such relationships may likewise be achieved by assigningstorage for the fields with locations in a computer-readable medium thatconvey relationship between the fields. Any suitable mechanism may beused to establish a relationship between information in fields of a datastructure, including through the use of pointers, tags or othermechanisms that establish relationship between data elements.

The concepts described herein may be embodied as one or more methods, ofwhich an example has been provided. The acts performed as part of themethod may be ordered in any suitable way. Accordingly, embodiments maybe constructed in which acts are performed in an order different thanillustrated, which may include performing some acts simultaneously, eventhough shown as sequential acts in illustrative embodiments.

As used herein, the terms “light”, “optical” and related terms shouldnot but understood to refer solely to electromagnetic radiation in thevisible spectrum, but instead generally refer to electromagneticradiation in the ultraviolet (about 10 nm to 390 nm), visible (390 nm to750 nm), near infrared (750 nm to 1400 nm), mid-infrared (1400 nm to15,000 nm), and far infrared (15,000 nm to about 1 mm).

The indefinite articles “a” and “an,” as used herein in thespecification and in the claims, unless clearly indicated to thecontrary, should be understood to mean “at least one.”

References to “or” may be construed as inclusive so that any termsdescribed using “or” may indicate any of a single, more than one, andall of the described terms.

In the claims, as well as in the specification above, all transitionalphrases such as “comprising,” “including.” “carrying.” “having,”“containing,” “involving,” “holding.” “composed of,” and the like are tobe understood to be open-ended, i.e., to mean including but not limitedto.

What is claimed is:
 1. A system for probing a workpiece using a workingmember, the system comprising: one or more processors; a sensor coupledto at least one of the one or more processors; a rig, wherein the sensoris coupled to the rig, and, with the working member not in contact withthe workpiece, at least a portion of the weight of the rig is supportedby the workpiece; one or more actuators configured to move the workingmember relative to the workpiece; and one or more memories operativelycoupled to the one or more processors and storing instructions which,when executed by the one or more processors, cause performance of:detecting a first value of a parameter measured by the sensor, wherein,during detection of the first value: the working member is not incontact with the workpiece, the working member is at a first lateralposition, and the sensor is at a first sensor position; providinginformation that causes at least one of the one or more of the actuatorsto move the working member into contact with the workpiece; detecting asecond value of the parameter measured by the sensor, wherein, duringdetection of the second value: the working member is in contact with theworkpiece, the working member is at the first lateral position, and thesensor is at a second sensor position; and determining a firstcalibrated position of the working member at the first lateral positionbased at least in part upon the first value and the second value,wherein the second sensor position is different from the first sensorposition.
 2. The system of claim 1, wherein the first value is relatedto force applied to the sensor, and the sensor is a force sensor.
 3. Thesystem of claim 1, wherein the first value is related to motion of thesensor, and the sensor is an inertial sensor.
 4. The system of claim 1,wherein the sensor is a camera, and the first value is related to animage pixel value from an image captured by the camera.
 5. The system ofclaim 1, wherein the one or more memories store instructions which, whenexecuted by the one or more processors, cause performance of: detectinga third value of the parameter measured by the sensor, wherein, duringdetection of the third value, the working member is at a second lateralposition; and determining a second calibrated position of the workingmember based at least in part upon the third value.
 6. The system ofclaim 5, wherein, during detection of the third value, the workingmember is in contact with a surface supporting the workpiece, and athickness value associated with the workpiece is based at least in partupon the first calibrated position and the second calibrated position.7. The system of claim 5, wherein, during detection of the third value,the working member is in contact with the workpiece, and a depth valueassociated with the second lateral position is based at least in partupon the first calibrated position and the second calibrated position.8. The system of claim 7, wherein a topographical map associated withthe workpiece is based at least in part upon a plurality of depth valuesand their associated respective lateral positions.
 9. The system ofclaim 1, wherein the first calibrated position is associated with areference position along an axis perpendicular to at least a portion ofa surface of the workpiece.
 10. The system of claim 9, wherein theworking member is located at the first lateral position relative to theportion of the surface of the workpiece.
 11. The system of claim 10,wherein, in a coordinate system, the first lateral position refers to xand y coordinates of a feature of the working member, and the firstcalibrated position refers to the z coordinate of the feature of theworking member.
 12. The system of claim 11, wherein the working memberis a cutting bit, and the feature is a tip of the cutting bit.
 13. Thesystem of claim 9, wherein the one or more memories store instructionswhich, when executed by the one or more processors, cause performanceof: cutting the workpiece at a second lateral position using the workingmember, wherein a position of the working member along the perpendicularaxis is based at least in part upon the first calibrated position and atarget cut depth.
 14. A computer implemented method for probing aworkpiece using a working member, the method comprising: detecting afirst value of a parameter measured by a sensor, wherein, the sensor iscoupled to a rig, at least a portion of the weight of the rig issupported by the workpiece with the working member not in contact withthe workpiece, and during detection of the first value: the workingmember is not in contact with the workpiece, the working member is at afirst lateral position, and the sensor is at a first sensor position;providing information that causes at least one of one or more actuatorsto move the working member into contact with the workpiece; detecting asecond value of the parameter measured by the sensor, wherein, duringdetection of the second value: the working member is in contact with theworkpiece, the working member is at the first lateral position, and thesensor is at a second sensor position; and determining a firstcalibrated position of the working member at the first lateral positionbased at least in part upon the first value and the second value,wherein the second sensor position is different from the first sensorposition.
 15. The method of claim 14, comprising: detecting a thirdvalue of the parameter measured by the sensor, wherein, during detectionof the third value, the working member is at a second lateral position;and determining a second calibrated position of the working member basedat least in part upon the third value.
 16. The method of claim 15,wherein, during detection of the third value, the working member is incontact with a surface supporting the workpiece, and a thickness valueassociated with the workpiece is based at least in part upon the firstcalibrated position and the second calibrated position.
 17. The methodof claim 15, wherein, during detection of the third value, the workingmember is in contact with the workpiece, and a depth value associatedwith the second lateral position is based at least in part upon thefirst calibrated position and the second calibrated position.
 18. Themethod of claim 17, wherein a topographical map associated with theworkpiece is based at least in part upon a plurality of depth values andtheir associated respective lateral positions.
 19. One or morenon-transitory computer-readable media storing instructions for probinga workpiece using a working member, wherein the instructions, whenexecuted by one or more processors, cause performance of: detecting afirst value of a parameter measured by a sensor, wherein, the sensor iscoupled to a rig, at least a portion of the weight of the rig issupported by the workpiece with the working member not in contact withthe workpiece, and during detection of the first value: the workingmember is not in contact with the workpiece, the working member is at afirst lateral position, and the sensor is at a first sensor position;providing information that causes at least one of one or more actuatorsto move the working member into contact with the workpiece; detecting asecond value of the parameter measured by the sensor, wherein, duringdetection of the second value: the working member is in contact with theworkpiece, the working member is at the first lateral position, and thesensor is at a second sensor position; and determining a firstcalibrated position of the working member at the first lateral positionbased at least in part upon the first value and the second value,wherein the second sensor position is different from the first sensorposition.
 20. The one or more non-transitory computer-readable media ofclaim 19, wherein the instructions, when executed by one or moreprocessors, cause performance of: detecting a third value of theparameter measured by the sensor, wherein, during detection of the thirdvalue, the working member is at a second lateral position; anddetermining a second calibrated position of the working member based atleast in part upon the third value.
 21. The one or more non-transitorycomputer-readable media of claim 20, wherein, during detection of thethird value, the working member is in contact with a surface supportingthe workpiece, and a thickness value associated with the workpiece isbased at least in part upon the first calibrated position and the secondcalibrated position.
 22. The one or more non-transitorycomputer-readable media of claim 20, wherein, during detection of thethird value, the working member is in contact with the workpiece, and adepth value associated with the second lateral position is based atleast in part upon the first calibrated position and the secondcalibrated position.
 23. The one or more non-transitorycomputer-readable media of claim 22, wherein a topographical mapassociated with the workpiece is based at least in part upon a pluralityof depth values and their associated respective lateral positions.